U.S. patent application number 16/926823 was filed with the patent office on 2020-10-29 for textured fibrous structures.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to John Daniel Algers, Douglas Jay Barkey, Steven Lee Barnholtz, Kamilah Gbadamosi Gillispie, Timothy Duane Smith, Michael Donald Suer, Fei Wang, Christopher Michael Young.
Application Number | 20200340176 16/926823 |
Document ID | / |
Family ID | 1000004954173 |
Filed Date | 2020-10-29 |
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United States Patent
Application |
20200340176 |
Kind Code |
A1 |
Suer; Michael Donald ; et
al. |
October 29, 2020 |
Textured Fibrous Structures
Abstract
Textured fibrous structures, and more particularly textured
fibrous structures having a plurality of deformations such that the
textures fibrous structures exhibit novel surface height properties
compared to known fibrous structures, and methods for making such
textured fibrous structures.
Inventors: |
Suer; Michael Donald;
(Colerain Township, OH) ; Wang; Fei; (Mason,
OH) ; Algers; John Daniel; (Montgomery, OH) ;
Young; Christopher Michael; (Loveland, OH) ;
Barnholtz; Steven Lee; (West Chester, OH) ; Smith;
Timothy Duane; (Lebanon, OH) ; Barkey; Douglas
Jay; (Salem Township, OH) ; Gillispie; Kamilah
Gbadamosi; (West Chester, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
1000004954173 |
Appl. No.: |
16/926823 |
Filed: |
July 13, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15209879 |
Jul 14, 2016 |
10711395 |
|
|
16926823 |
|
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62196491 |
Jul 24, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06N 2209/106 20130101;
D06N 7/00 20130101; D21H 27/02 20130101; D06N 2211/24 20130101;
D10B 2509/02 20130101; D21H 27/002 20130101 |
International
Class: |
D06N 7/00 20060101
D06N007/00; D21H 27/00 20060101 D21H027/00; D21H 27/02 20060101
D21H027/02 |
Claims
1. A pre-moistened textured fibrous structure comprising a first
surface and a second surface wherein each of the first and second
surfaces comprises a plurality of deformations such that at least
one of the first and second surfaces exhibits an average absolute
surface height value (Sa) of greater than 250 .mu.m as measured
according to the Surface Height Test Method and wherein the average
absolute surface height value (Sa) for the first and second
surfaces differs by less than 10%.
2. The pre-moistened textured fibrous structure according to claim
1 wherein the pre-moistened textured fibrous structure comprises a
plurality of fibrous elements.
3. The pre-moistened textured fibrous structure according to claim
2 wherein the fibrous elements comprise a plurality of
filaments.
4. The pre-moistened textured fibrous structure according to claim
2 wherein the fibrous elements comprise a plurality of filaments
and fibers commingled together.
5. The pre-moistened textured fibrous structure according to claim
2 wherein at least one of the fibrous elements comprises a
thermoplastic polymer.
6. The pre-moistened textured fibrous structure according to claim
2 wherein the fibrous elements comprise a plurality of fibers.
7. A multi-ply pre-moistened textured fibrous structure comprising
two or more of the pre-moistened textured fibrous structures
according to claim 1 such that surfaces of the pre-moistened
textured fibrous structure form exterior surfaces of the multi-ply
fibrous structure.
8. A pre-moistened textured fibrous structure comprising a first
surface and a second surface wherein each of the first and second
surfaces comprises a plurality of deformations such that at least
one of the first and second surfaces exhibits a root mean square
average surface height value (Sq) of greater than 300 .mu.m as
measured according to the Surface Height Test Method and wherein
the root mean square average surface height value (Sq) for the
first and second surfaces differs by less than 10%.
9. The textured fibrous structure according to claim 8 wherein the
textured fibrous structure comprises a plurality of fibrous
elements.
10. The textured fibrous structure according to claim 9 wherein the
fibrous elements comprise a plurality of filaments.
11. The textured fibrous structure according to claim 9 wherein the
fibrous elements comprise a plurality of filaments and fibers
commingled together.
12. The textured fibrous structure according to claim 9 wherein at
least one of the fibrous elements comprises a thermoplastic
polymer.
13. The textured fibrous structure according to claim 9 wherein the
fibrous elements comprise a plurality of fibers.
14. A multi-ply textured fibrous structure comprising two or more
of the textured fibrous structures according to claim 8 such that
surfaces of the textured fibrous structure form exterior surfaces
of the multi-ply fibrous structure.
15. A textured fibrous structure comprising at least one surface
comprising a plurality of deformations such that the surface
exhibits a height difference surface height value (Sk) of greater
than 825 .mu.m as measured according to the Surface Height Test
Method.
16. The textured fibrous structure according to claim 15 wherein
the textured fibrous structure comprises a plurality of fibrous
elements.
17. The textured fibrous structure according to claim 16 wherein
the fibrous elements comprise a plurality of filaments.
18. The textured fibrous structure according to claim 16 wherein
the fibrous elements comprise a plurality of filaments and fibers
commingled together.
19. The textured fibrous structure according to claim 16 wherein at
least one of the fibrous elements comprises a thermoplastic
polymer.
20. A multi-ply textured fibrous structure comprising two or more
of the textured fibrous structures according to claim 15 such that
surfaces of the textured fibrous structure form exterior surfaces
of the multi-ply fibrous structure.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to textured fibrous
structures, and more particularly to textured fibrous structures
comprising a plurality of deformations such that the textured
fibrous structures exhibit novel surface height properties compared
to known fibrous structures, and methods for making such textured
fibrous structures.
BACKGROUND OF THE INVENTION
[0002] Textured fibrous structures comprising filaments are known
in the art. However, consumers of such known textured fibrous
structures, which exhibit relatively low surface height properties,
desire higher surface height properties in their textured fibrous
structures.
[0003] As shown in FIGS. 1A-1B, an example of a prior art textured
fibrous structure 10, in this case a textured spunlaced fibrous
structure, exhibits a relatively flat surface 12 into which a
pattern or in this case one or more objects 14, such as a butterfly
and/or heart, is depressed into the flat surface 12. Such a prior
art textured fibrous structure 10 exhibits lower surface height
properties than are desired by consumers.
[0004] As shown in FIGS. 2A-2B, another example of a prior art
textured fibrous structure 10 exhibits a relatively flat surface 12
into which a pattern or in this case one or more objects 14, such
as a duck and/or a leaf, is depressed into the flat surface 12.
Such a prior art textured fibrous structure 10 exhibits low surface
height properties than are desired by consumers.
[0005] One problem with known textured fibrous structures, for
example known textured fibrous structures comprising a plurality of
filaments, is that they exhibit lower than desirable surface height
properties such that less than desirable actual and/or perceived
bowel movement removal during use by consumers is experienced.
[0006] To date, manufacturers of known filament-containing fibrous
structures have not imparted texture to at least one surface of the
known filament-containing fibrous structures that achieves the
surface height properties desired by consumers. In the past,
manufacturers of filament-containing fibrous structures have
utilized patterned thermal bonding rolls, such as point bond
patterns and/or objects, such as butterflies and ducks, to bond its
filaments and materials together to give such fibrous structures
integrity, but have not imparted sufficient texture into at least
one of the surfaces such that the fibrous structures exhibit
greater surface height properties to meet the consumers' needs.
[0007] Accordingly, there is a need for textured fibrous
structures, for example textured fibrous structures comprising a
plurality of filaments, that exhibit greater surface height
properties compared to known textured fibrous structures, for
example known textured fibrous structures comprising a plurality of
filaments, and thus improved actual and/or perceived bowel movement
cleaning, and methods for making such textured fibrous
structures.
SUMMARY OF THE INVENTION
[0008] The present invention fulfills the needs described above by
providing textured fibrous structures, for example textured fibrous
structures comprising a plurality of filaments, that exhibit
greater surface height properties compared to known textured
fibrous structures, for example known textured fibrous structures
comprising a plurality of filaments, and thus improved actual
and/or perceived bowel movement cleaning, and methods for making
such textured fibrous structures.
[0009] One solution to the problem identified above is to produce a
textured fibrous structure, for example a textured fibrous
structure comprising a plurality of filaments and/or comprising a
liquid composition, such as a lotion composition, comprising at
least one surface comprising a plurality of deformations
(protrusions and/or depressions) such that the surface of the
textured fibrous structure exhibits one or more of the following
surface height properties desirable to consumers of the textured
fibrous structures for improved actual and/or perceived bowel
movement cleaning: an average absolute surface height value (Sa) of
greater than 250 .mu.m, a root mean square average surface height
value (Sq) of greater than 300 .mu.m, and/or a height difference
surface height value (Sk) of greater than 825 .mu.m as measured
according to the Surface Height Test Method is provided.
[0010] In one example of the present invention, a textured fibrous
structure, for example a textured fibrous structure comprising a
plurality of filaments and/or comprising a liquid composition, such
as a lotion composition, comprising at least one surface comprising
a plurality of deformations (protrusions and/or depressions) such
that the surface of the textured fibrous structure exhibits an
average absolute surface height value (Sa) of greater than 250
.mu.m as measured according to the Surface Height Test Method is
provided.
[0011] In another example of the present invention, a textured
fibrous structure, for example a textured fibrous structure
comprising a plurality of filaments and/or comprising a liquid
composition, such as a lotion composition, comprising at least one
surface comprising a plurality of deformations (protrusions and/or
depressions) such that the surface of the textured fibrous
structure exhibits a root mean square average surface height value
(Sq) of greater than 300 .mu.m as measured according to the Surface
Height Test Method is provided.
[0012] In another example of the present invention, a textured
fibrous structure, for example a textured fibrous structure
comprising a plurality of filaments and/or comprising a liquid
composition, such as a lotion composition, comprising at least one
surface comprising a plurality of deformations (protrusions and/or
depressions) such that the surface of the textured fibrous
structure exhibits a height difference surface height value (Sk) of
greater than 825 .mu.m as measured according to the Surface Height
Test Method is provided.
[0013] In still another example of the present invention, a single-
or multi-ply sanitary tissue product comprising at least one
textured fibrous structure, for example a textured fibrous
structure comprising a plurality of filaments and/or comprising a
liquid composition, such as a lotion composition, according to the
present invention is provided.
[0014] In yet another example of the present invention, a process
for making a textured fibrous structure, for example a textured
fibrous structure comprising a plurality of filaments and/or
comprising a liquid composition, such as a lotion composition,
according to the present invention comprises the step of imparting
deformations (protrusions and/or depressions) to at least one
surface of a fibrous structure, for example a fibrous structure
comprising a plurality of filaments, such that the surface of the
textured fibrous structure exhibits an average absolute surface
height value (Sa) of greater than 250 .mu.m as measured according
to the Surface Height Test Method is provided.
[0015] In yet another example of the present invention, a process
for making a textured fibrous structure, for example a textured
fibrous structure comprising a plurality of filaments and/or
comprising a liquid composition, such as a lotion composition,
according to the present invention comprises the step of imparting
deformations (protrusions and/or depressions) to at least one
surface of a fibrous structure, for example a fibrous structure
comprising a plurality of filaments, such that the surface of the
textured fibrous structure exhibits a root mean square average
surface height value (Sq) of greater than 300 .mu.m as measured
according to the Surface Height Test Method is provided.
[0016] In yet another example of the present invention, a process
for making a textured fibrous structure, for example a textured
fibrous structure comprising a plurality of filaments and/or
comprising a liquid composition, such as a lotion composition,
according to the present invention comprises the step of imparting
deformations (protrusions and/or depressions) to at least one
surface of a fibrous structure, for example a fibrous structure
comprising a plurality of filaments, such that the surface of the
textured fibrous structure exhibits a height difference surface
height value (Sk) of greater than 825 .mu.m as measured according
to the Surface Height Test Method is provided.
[0017] For consumers to experience the desired benefits of the
textured surface, it will in many cases cases be important that the
texture is consistent on either side of the fibrous textured
structure, such as the Sa, Sq, Sk values on one side of the fibrous
structure are similar, for example less than 10% and/or less than
5% and/or less than 3% and/or less than 1% difference between
values, to the respective values of Sa, Sq, Sk on the other side of
the fibrous structure. One way to create such fibrous structures is
to combine 2 identical plies of textured fibrous structures in such
a way that the external surface of the resulting 2-ply fibrous
structure has identical Sa, Sk, Sq values. In one example, the
fibrous structure plies may be bonded together, such as by thermal
bonding and/or adhesive bonding, to form a multi-ply textured
fibrous structure.
[0018] The present invention provides novel textured fibrous
structures, for example novel textured fibrous structures
comprising a plurality of filaments and/or comprising a liquid
composition, such as a lotion composition, that exhibit improved
surface height properties compared to known textured fibrous
structures, and methods for making same.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A is a schematic representation of an example of a
Prior Art textured fibrous structure;
[0020] FIG. 1B is a cross-sectional view of FIG. 1A taken along
line 1B-1B
[0021] FIG. 2A is a schematic representation of another example of
a Prior Art textured fibrous structure;
[0022] FIG. 2B is a cross-sectional view of FIG. 2A taken along
line 2B-2B
[0023] FIG. 3A is a perspective view of an example of textured
fibrous structure according to the present invention;
[0024] FIG. 3B is a cross-sectional view of FIG. 3A taken along
line 3B-3B;
[0025] FIG. 4 is a perspective view of another example of a
textured fibrous structure according to the present invention;
[0026] FIG. 5 is a top plan view of another example of a textured
fibrous structure according to the present invention;
[0027] FIG. 6 is a top plan view of another example of a textured
fibrous structure according to the present invention;
[0028] FIG. 7 is a top plan view of another example of a textured
fibrous structure according to the present invention;
[0029] FIG. 8 is an Element Characterization plot of area for the
textured fibrous structure of FIG. 5;
[0030] FIG. 9 is an Element Characterization plot of area for the
textured fibrous structure of FIG. 6;
[0031] FIG. 10 is an Element Characterization plot of area for the
textured fibrous structure of FIG. 7;
[0032] FIG. 11 is a perspective view of an example of a textured
fibrous structure according to the present invention;
[0033] FIG. 12 is a cross-sectional view of FIG. 11 taken along
line 12-12;
[0034] FIG. 13 is a perspective view of another example of a
fibrous structure according to the present invention;
[0035] FIG. 14 is a cross-sectional view of another example of a
fibrous structure according to the present invention;
[0036] FIG. 15 is a cross-sectional view of another example of a
fibrous structure according to the present invention;
[0037] FIG. 16 is a pressure mapping image for another prior art
textured fibrous structure;
[0038] FIG. 17 is a pressure mapping image of another prior art
textured fibrous structure; and
[0039] FIG. 18 is a pressure mapping image of a textured fibrous
structure according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0040] "Fibrous structure" as used herein means a structure that
comprises one or more fibrous elements, filaments and/or fibers. In
one example, the fibrous structure is a wipe, such as a wet wipe,
for example a baby wipe. In another example, the fibrous structure
is a paper towel, such as a dry paper towel. In one example, a
fibrous structure according to the present invention means an
orderly arrangement of filaments and/or fibers within a structure
in order to perform a function. In another example, a fibrous
structure according to the present invention is a nonwoven.
[0041] Non-limiting examples of processes for making fibrous
structures include known wet-laid papermaking processes, air-laid
papermaking processes including carded and/or spunlaced processes,
as well as meltblown and/or spunbond processes. Such wet-laid
and/or air-laid processes typically include steps of preparing a
fiber composition in the form of a suspension in a medium, either
wet, more specifically aqueous medium, or dry, more specifically
gaseous, i.e. with air as medium. The aqueous medium used for
wet-laid processes is oftentimes referred to as a fiber slurry. The
fibrous slurry is then used to deposit a plurality of fibers onto a
forming wire or belt such that an embryonic fibrous structure is
formed, after which drying and/or bonding the fibers together
results in a fibrous structure. Further processing the fibrous
structure may be carried out such that a finished fibrous structure
is formed. For example, in typical papermaking processes, the
finished fibrous structure is the fibrous structure that is wound
on the reel at the end of papermaking, and may subsequently be
converted into a finished product, e.g. a sanitary tissue
product.
[0042] The fibrous structures of the present invention may be
homogeneous or may be layered. If layered, the fibrous structures
may comprise at least two and/or at least three and/or at least
four and/or at least five layers.
[0043] In one example the fibrous structure is a nonwoven.
[0044] "Nonwoven" for purposes of the present invention as used
herein and as defined by EDANA means a sheet of fibers, continuous
filaments, or chopped yarns of any nature or origin, that have been
formed into a web by any means, and bonded together by any means,
with the exception of weaving or knitting. Felts obtained by wet
milling are not nonwovens. Wetlaid webs are nonwovens provided that
they contain a minimum of 50% by weight of man-made fibers,
filaments or other fibers of non-vegetable origin with a length to
diameter ratio that equals or exceeds 300 or a minimum of 30% by
weight of man-made fibers, filaments or other fibers of
non-vegetable origin with a length to diameter ratio that equals or
exceeds 600 and a maximum apparent density of 0.40 g/cm.sup.3.
[0045] The fibrous structures of the present invention may be
co-formed fibrous structures.
[0046] "Co-formed fibrous structure" as used herein means that the
fibrous structure comprises a mixture of at least two different
materials wherein at least one of the materials comprises a
filament, such as a polypropylene filament, and at least one other
material, different from the first material, comprises a solid
additive, such as a fiber and/or a particulate. In one example, a
co-formed fibrous structure comprises solid additives, such as
fibers, such as wood pulp fibers and/or absorbent gel materials
and/or filler particles and/or particulate spot bonding powders
and/or clays, and filaments, such as polypropylene filaments.
[0047] "Solid additive" as used herein means a fiber and/or a
particulate.
[0048] "Particulate" as used herein means a granular substance or
powder.
[0049] "Fiber" and/or "Filament" as used herein means an elongate
particulate having an apparent length greatly exceeding its
apparent width, i.e. a length to diameter ratio of at least about
10. For purposes of the present invention, a "fiber" is an elongate
particulate as described above that exhibits a length of less than
5.08 cm (2 in.) and a "filament" is an elongate particulate as
described above that exhibits a length of greater than or equal to
5.08 cm (2 in.).
[0050] Fibers are typically considered discontinuous in nature.
Non-limiting examples of fibers include wood pulp fibers, rayon,
which in turn includes but is not limited to viscose, lyocell,
cotton; wool; silk; jute; linen; ramie; hemp; flax; camel hair;
kenaf; and synthetic staple fibers made from polyester, nylons,
polyolefins such as polypropylene, polyethylene, natural polymers,
such as starch, starch derivatives, cellulose and cellulose
derivatives, hemicellulose, hemicellulose derivatives, chitin,
chitosan, polyisoprene (cis and trans), peptides,
polyhydroxyalkanoates, copolymers of polyolefins such as
polyethylene-octene, and biodegradable or compostable thermoplastic
fibers such as polylactic acid filaments, polyvinyl alcohol
filaments, and polycaprolactone filaments. The fibers may be
monocomponent or multicomponent, such as bicomponent filaments,
round, non-round fibers; and combinations thereof.
[0051] Filaments are typically considered continuous or
substantially continuous in nature. Filaments are relatively longer
than fibers. Non-limiting examples of filaments include meltblown
and/or spunbond filaments. Non-limiting examples of materials that
can be spun into filaments include natural polymers, such as
starch, starch derivatives, cellulose and cellulose derivatives,
hemicellulose, hemicellulose derivatives, chitin, chitosan,
polyisoprene (cis and trans), peptides, polyhydroxyalkanoates, and
synthetic polymers including, but not limited to, thermoplastic
polymer filaments comprising thermoplastic polymers, such as
polyesters, nylons, polyolefins such as polypropylene filaments,
polyethylene filaments, polyvinyl alcohol and polyvinyl alcohol
derivatives, sodium polyacrylate (absorbent gel material)
filaments, and copolymers of polyolefins such as
polyethylene-octene, and biodegradable or compostable thermoplastic
fibers such as polylactic acid filaments, polyvinyl alcohol
filaments, and polycaprolactone filaments. The filaments may be
monocomponent or multicomponent, such as bicomponent filaments.
[0052] In one example of the present invention, "fiber" refers to
papermaking fibers. Papermaking fibers useful in the present
invention include cellulosic fibers commonly known as wood pulp
fibers. Applicable wood pulps include chemical pulps, such as
Kraft, sulfite, and sulfate pulps, as well as mechanical pulps
including, for example, groundwood, thermomechanical pulp and
chemically modified thermomechanical pulp. Chemical pulps, however,
may be preferred since they impart a superior tactile sense of
softness to tissue sheets made therefrom. Pulps derived from both
deciduous trees (hereinafter, also referred to as "hardwood") and
coniferous trees (hereinafter, also referred to as "softwood") may
be utilized. The hardwood and softwood fibers can be blended, or
alternatively, can be deposited in layers to provide a stratified
web. U.S. Pat. Nos. 4,300,981 and 3,994,771 are incorporated herein
by reference for the purpose of disclosing layering of hardwood and
softwood fibers. Also applicable to the present invention are
fibers derived from recycled paper, which may contain any or all of
the above categories as well as other non-fibrous materials such as
fillers and adhesives used to facilitate the original
papermaking.
[0053] In addition to the various wood pulp fibers, other
cellulosic fibers such as cotton linters, rayon, lyocell and
bagasse can be used in this invention. Other sources of cellulose
in the form of fibers or capable of being spun into fibers include
grasses and grain sources.
[0054] "Sanitary tissue product" as used herein means a soft, low
density (i.e. <about 0.15 g/cm.sup.3) web useful as a wiping
implement for post-urinary and post-bowel movement cleaning (toilet
tissue), for otorhinolaryngological discharges (facial tissue), and
multi-functional absorbent and cleaning uses (absorbent towels).
Non-limiting examples of suitable sanitary tissue products of the
present invention include paper towels, bath tissue, facial tissue,
napkins, baby wipes, adult wipes, wet wipes, cleaning wipes,
polishing wipes, cosmetic wipes, car care wipes, wipes that
comprise an active agent for performing a particular function,
cleaning substrates for use with implements, such as a Swifter.RTM.
cleaning wipe/pad. The sanitary tissue product may be convolutedly
wound upon itself about a core or without a core to form a sanitary
tissue product roll.
[0055] In one example, the sanitary tissue product of the present
invention comprises a fibrous structure according to the present
invention.
[0056] The sanitary tissue products of the present invention may
exhibit a basis weight between about 10 g/m.sup.2 to about 500
g/m.sup.2 and/or from about 15 g/m.sup.2 to about 400 g/m.sup.2
and/or from about 20 g/m.sup.2 to about 300 g/m.sup.2 and/or from
about 20 g/m.sup.2 to about 200 g/m.sup.2 and/or from about 20
g/m.sup.2 to about 150 g/m.sup.2 and/or from about 20 g/m.sup.2 to
about 120 g/m.sup.2 and/or from about 20 g/m.sup.2 to about 110
g/m.sup.2 and/or from about 20 g/m.sup.2 to about 100 g/m.sup.2
and/or from about 30 to 90 g/m.sup.2. In addition, the sanitary
tissue product of the present invention may exhibit a basis weight
between about 40 g/m.sup.2 to about 500 g/m.sup.2 and/or from about
50 g/m.sup.2 to about 400 g/m.sup.2 and/or from about 55 g/m.sup.2
to about 300 g/m.sup.2 and/or from about 60 to 200 g/m.sup.2. In
one example, the sanitary tissue product exhibits a basis weight of
less than 100 g/m.sup.2 and/or less than 80 g/m.sup.2 and/or less
than 75 g/m.sup.2 and/or less than 70 g/m.sup.2 and/or less than 65
g/m.sup.2 and/or less than 60 g/m.sup.2 and/or less than 55
g/m.sup.2 and/or less than 50 g/m.sup.2 and/or less than 47
g/m.sup.2 and/or less than 45 g/m.sup.2 and/or less than 40
g/m.sup.2 and/or less than 35 g/m.sup.2 and/or to greater than 20
g/m.sup.2 and/or greater than 25 g/m.sup.2 and/or greater than 30
g/m.sup.2 as measured according to the Basis Weight Test Method
described herein.
[0057] In one example, the sanitary tissue product of the present
invention may exhibit a CD Wet Initial Tensile Strength of/or
greater than 5.0 N and/or greater than 5.5 N and/or greater than
6.0 N as measured according to the CD Wet Initial Tensile Strength
Test Method described herein.
[0058] The sanitary tissue products of the present invention may
exhibit a density (measured at 95 g/in.sup.2) of less than about
0.60 g/cm.sup.3 and/or less than about 0.30 g/cm.sup.3 and/or less
than about 0.20 g/cm.sup.3 and/or less than about 0.10 g/cm.sup.3
and/or less than about 0.07 g/cm.sup.3 and/or less than about 0.05
g/cm.sup.3 and/or from about 0.01 g/cm.sup.3 to about 0.20
g/cm.sup.3 and/or from about 0.02 g/cm.sup.3 to about 0.10
g/cm.sup.3.
[0059] The sanitary tissue products of the present invention may
comprises additives such as softening agents, temporary wet
strength agents, permanent wet strength agents, bulk softening
agents, silicones, wetting agents, latexes, especially
surface-pattern-applied latexes, dry strength agents such as
carboxymethylcellulose and starch, and other types of additives
suitable for inclusion in and/or on sanitary tissue products.
[0060] "Deformations" as used herein means surface height
("z"-oriented) objects; namely, protrusions 16 and/or depressions
18 on a surface 12 of the textured fibrous structure 10 as shown in
FIGS. 3A, 3B and 4. The deformations may be out-of-plane portions
of the surface of the textured fibrous structure. In one example,
at least one surface of the textured fibrous structure of the
present invention comprises a plurality of discrete deformations,
for example a plurality of discrete protrusions and/or a plurality
of discrete depressions. In one example, the textured fibrous
structure comprises a first surface comprising a plurality of
discrete protrusions and a second surface, opposite the first
surface, comprising a plurality of discrete depressions. In another
example, the textured fibrous structure comprises a first surface
comprising a plurality of discrete protrusions and a second
surface, opposite the first surface, comprising a plurality of
discrete depressions, wherein at least one of the discrete
protrusions and one of the discrete depressions are registered with
one another in a one-to-one relationship.
[0061] Further, the plurality of deformations on a surface of the
textured fibrous structure are present in a non-random, repeating
pattern, for example a single deformation may be in the shape of an
object, such as a heart, a butterfly, a leaf, a flower, and not
simply a geometric shape. In another example, two or more or three
or more discrete deformations may together form a design or object,
such as a flower (petals of the flower). Such designs and/or
objects are achievable using patterned resinous belts and/or
patterned rolls to impart the deformations to the fibrous structure
and have not been achievable using woven fabrics to impart texture,
if any, to fibrous structures.
[0062] "Elements" as used herein means an x-y plane of a
deformation; namely, an x-y plane of a protrusion and an x-y plane
of a depression. The elements and their characteristics, such as
area, perimeter, aspect ratio, angle (such as feret angle),
inter-element distances, etc. are determined and measured according
to the Element Characterization Test Method described herein. In
one example, the textured fibrous structure of the present
invention comprises at least one surface comprising greater than
10% and/or greater than 15% and/or greater than 20% and/or greater
than 25% and/or greater than 30% and/or greater than 35% of
elements that exhibits an average area of greater than 10 mm.sup.2
and/or greater than 15 mm.sup.2 and/or greater than 20 mm.sup.2
and/or greater than 25 mm.sup.2 and/or greater than 30 mm.sup.2 as
measured according to the Element Characterization Test Method
described herein.
[0063] "Basis Weight" as used herein is the weight per unit area of
a sample reported in lbs/3000 ft.sup.2 or g/m.sup.2 (gsm).
[0064] "Stack" as used herein, refers to a neat pile of fibrous
structures and/or wipes. Based upon the assumption that there are
at least three wipes in a stack, each wipe, except for the topmost
and bottommost wipes in the stack, will be directly in face to face
contact with the wipe directly above and below itself in the stack.
Moreover, when viewed from above, the wipes will be layered on top
of each other, or superimposed, such that only the topmost wipe of
the stack will be visible. The height of the stack is measured from
the bottom of the bottommost wipe in the stack to the top of the
topmost wipe in the stack and is provided in units of millimeters
(mm).
[0065] "Liquid composition" and "lotion" are used interchangeably
herein and refer to any liquid, including, but not limited to a
pure liquid such as water, an aqueous solution, a colloid, an
emulsion, a suspension, a solution and mixtures thereof. The term
"aqueous solution" as used herein, refers to a solution that is at
least about 20% and/or at least about 40% and/or at least about 50%
water by weight, and is no more than 99.9% and/or no more than
about 99% and/or no more than about 98% and/or no more than about
97% and/or no more than about 95% and/or no more than about 90%
water by weight.
[0066] In one example, the liquid composition comprises water or
another liquid solvent. Generally the liquid composition is of
sufficiently low viscosity to impregnate the entire structure of
the fibrous structure. In another example, the liquid composition
may be primarily present at the fibrous structure surface and to a
lesser extent in the inner structure of the fibrous structure. In a
further example, the liquid composition is releasably carried by
the fibrous structure, that is the liquid composition is carried on
or in the fibrous structure and is readily releasable from the
fibrous structure by applying some force to the fibrous structure,
for example by wiping a surface with the fibrous structure.
[0067] The liquid compositions used in the present invention are
primarily although not limited to, oil in water emulsions. In one
example, the liquid composition of the present invention comprises
at least 80% and/or at least 85% and/or at least 90% and/or at
least 95% by weight water.
[0068] When present on or in the fibrous structure, the liquid
composition may be present at a level of from about 10% to about
1000% of the basis weight of the fibrous structure and/or from
about 100% to about 700% of the basis weight of the fibrous
structure and/or from about 200% to about 500% and/or from about
200% to about 400% of the basis weight of the fibrous
structure.
[0069] The liquid composition may comprise an acid. Non-limiting
examples of acids that can be used in the liquid composition of the
present invention are adipic acid, tartaric acid, citric acid,
maleic acid, malic acid, succinic acid, glycolic acid, glutaric
acid, malonic acid, salicylic acid, gluconic acid, polymeric acids,
phosphoric acid, carbonic acid, fumaric acid and phthalic acid and
mixtures thereof. Suitable polymeric acids can include
homopolymers, copolymers and terpolymers, and may contain at least
30 mole % carboxylic acid groups. Specific examples of suitable
polymeric acids useful herein include straight-chain poly(acrylic)
acid and its copolymers, both ionic and nonionic, (e.g.,
maleic-acrylic, sulfonic-acrylic, and styrene-acrylic copolymers),
those cross-linked polyacrylic acids having a molecular weight of
less than about 250,000, preferably less than about 100,000 poly
(.alpha.-hydroxy) acids, poly (methacrylic) acid, and naturally
occurring polymeric acids such as carageenic acid, carboxy methyl
cellulose, and alginic acid. In one example, the liquid composition
comprises citric acid and/or citric acid derivatives.
[0070] The liquid composition may also contain salts of the acid or
acids used to lower the pH, or another weak base to impart
buffering properties to the fibrous structure. The buffering
response is due to the equilibrium which is set up between the free
acid and its salt. This allows the fibrous structure to maintain
its overall pH despite encountering a relatively high amount of
bodily waste as would be found post urination or defecation in a
baby or adult. In one embodiment the acid salt would be sodium
citrate. The amount of sodium citrate present in the lotion would
be between 0.01 and 2.0%, alternatively 0.1 and 1.25%, or
alternatively 0.2 and 0.7% of the lotion.
[0071] In one example, the liquid composition does not contain any
preservative compounds.
[0072] In addition to the above ingredients, the liquid composition
may comprise addition ingredients. Non-limiting examples of
additional ingredients that may be present in the liquid
composition of the present invention include: skin conditioning
agents (emollients, humectants) including, waxes such as
petrolatum, cholesterol and cholesterol derivatives, di and
tri-glycerides including sunflower oil and sesame oil, silicone
oils such as dimethicone copolyol, caprylyl glycol and
acetoglycerides such as lanolin and its derivatives, emulsifiers;
stabilizers; surfactants including anionic, amphoteric, cationic
and non ionic surfactants, colourants, chelating agents including
EDTA, sun screen agents, solubilizing agents, perfumes, opacifying
agents, vitamins, viscosity modifiers; such as xanthan gum,
astringents and external analgesics.
[0073] "Pre-moistened" and "wet" are used interchangeably herein
and refer to fibrous structures and/or wipes which are moistened
with a liquid composition prior to packaging in a generally
moisture impervious container or wrapper. Such pre-moistened wipes,
which can also be referred to as "wet wipes" and "towelettes", may
be suitable for use in cleaning babies, as well as older children
and adults.
[0074] "Saturation loading" and "lotion loading" are used
interchangeably herein and refer to the amount of liquid
composition applied to the fibrous structure or wipe. In general,
the amount of liquid composition applied may be chosen in order to
provide maximum benefits to the end product comprised by the wipe.
Saturation loading is typically expressed as grams of liquid
composition per gram of dry wipe.
[0075] Saturation loading, often expressed as percent saturation,
is defined as the percentage of the dry fibrous structure or wipe's
mass (void of any liquid composition) that a liquid composition
present on/in the fibrous structure or wipe represents. For
example, a saturation loading of 1.0 (equivalently, 100%
saturation) indicates that the mass of liquid composition present
on/in the fibrous structure or wipe is equal to the mass of dry
fibrous structure or wipe (void of any liquid composition).
[0076] The following equation is used to calculate saturation load
of a fibrous structure or wipe:
Saturation Loading = [ wet wipe mass ( wipe size ) * ( basis weight
) ] - 1 ##EQU00001##
[0077] "Saturation gradient index" (SGI) is a measure of how well
the wipes at the top of a stack retain moisture. The SGI of a stack
of wipes is measured as described infra and is calculated as the
ratio of the average lotion load of the bottommost wipes in the
stack versus the topmost wipes in the stack. The ideal stack of
wipes will have an SGI of about 1.0; that is, the topmost wipes
will be equally as moist as the bottommost wipes. In the
aforementioned embodiments, the stacks have a SGI from about 1.0 to
about 1.5.
[0078] The saturation gradient index for a fibrous structure or
wipe stack is calculated as the ratio of the saturation loading of
a set number of fibrous structures or wipes from the bottom of a
stack to that of the same number of fibrous structures or wipes
from the top of the stack. For example, for an approximately 80
count wipe stack, the saturation gradient index is this ratio using
10 wipes from bottom and top; for an approximately 30 count wipe
stack, 5 wipes from bottom and top are used; and for less than 30,
only the top and bottom single wipes are used in the saturation
gradient index calculation. The following equation illustrates the
example of an 80 count stack saturation gradient index
calculation:
Saturation Gradient Index = average lotion load of bottom 10 wipes
in stack average lotion load of top 10 wipes in stack
##EQU00002##
[0079] A saturation profile, or wetness gradient, exists in the
stack when the saturation gradient index is greater than 1.0. In
cases where the saturation gradient index is significantly greater
than 1.0, e.g. over about 1.5, lotion is draining from the top of
the stack and settling in the bottom of the container, such that
there may be a noticeable difference in the wetness of the topmost
fibrous structures or wipes in the stack compared to that of the
fibrous structures or wipes nearest the bottom of the stack. For
example, a perfect tub of wipes would have a saturation gradient
index of 1.0; the bottommost wipes and topmost wipes would maintain
equivalent saturation loading during storage. Additional liquid
composition would not be needed to supersaturate the wipes in an
effort to keep all of the wipes moist, which typically results in
the bottommost wipes being soggy.
[0080] "Percent moisture" or "% moisture" or "moisture level" as
used herein means 100.times.(the ratio of the mass of water
contained in a fibrous structure to the mass of the fibrous
structure). The product of the above equation is reported as a
%.
[0081] "Surface tension" as used herein, refers to the force at the
interface between a liquid composition and air. Surface tension is
typically expressed in dynes per centimeter (dynes/cm).
[0082] "Surfactant" as used herein, refers to materials which
preferably orient toward an interface. Surfactants include the
various surfactants known in the art, including: nonionic
surfactants; anionic surfactants; cationic surfactants; amphoteric
surfactants, zwitterionic surfactants; and mixtures thereof.
[0083] "Visible" as used herein, refers to being capable of being
seen by the naked eye when viewed at a distance of 12 inches (in),
or 30.48 centimeters (cm), under the unimpeded light of an ordinary
incandescent 60 watt light bulb that is inserted in a fixture such
as a table lamp. It follows that "visually distinct" as used herein
refers to those features of nonwoven wipes, whether or not they are
pre-moistened, that are readily visible and discernable when the
wipe is subjected to normal use, such as the cleaning of a child's
skin.
[0084] "Machine Direction" or "MD" as used herein means the
direction parallel to the flow of the fibrous structure through the
fibrous structure making machine and/or sanitary tissue product
manufacturing equipment.
[0085] "Cross Machine Direction" or "CD" as used herein means the
direction parallel to the width of the fibrous structure making
machine and/or sanitary tissue product manufacturing equipment and
perpendicular to the machine direction.
[0086] "Ply" as used herein means an individual, integral fibrous
structure. "Plies" as used herein means two or more individual,
integral fibrous structures disposed in a substantially contiguous,
face-to-face relationship with one another, forming a multi-ply
fibrous structure and/or multi-ply sanitary tissue product. It is
also contemplated that an individual, integral fibrous structure
can effectively form a multi-ply fibrous structure, for example, by
being folded on itself.
[0087] "Total Pore Volume" as used herein means the sum of the
fluid holding void volume in each pore range from 2.4 .mu.m to 1000
.mu.m radii as measured according to the Pore Volume Test Method
described herein.
[0088] "Pore Volume Distribution" as used herein means the
distribution of fluid holding void volume as a function of pore
radius. The Pore Volume Distribution of a fibrous structure is
measured according to the Pore Volume Test Method described
herein.
[0089] As used herein, the articles "a" and "an" when used herein,
for example, "an anionic surfactant" or "a fiber" is understood to
mean one or more of the material that is claimed or described.
[0090] All percentages and ratios are calculated by weight unless
otherwise indicated. All percentages and ratios are calculated
based on the total composition unless otherwise indicated.
[0091] Unless otherwise noted, all component or composition levels
are in reference to the active level of that component or
composition, and are exclusive of impurities, for example, residual
solvents or by-products, which may be present in commercially
available sources.
Fibrous Structure
[0092] It has surprisingly been found that the textured fibrous
structures of the present invention that exhibit novel surface
height properties compared to known textured fibrous structures
provide consumers with improved actual and/or perceived bowel
movement removal during use.
[0093] In one example, a textured fibrous structure, for example a
textured fibrous structure comprising a plurality of filaments
and/or comprising a liquid composition, such as a lotion, according
to the present invention comprises at least one surface comprising
a plurality of deformations such that the surface exhibits one or
more of the following surface height properties: [0094] a. an
average absolute surface height value (Sa) of greater than 250
.mu.m and/or greater than 275 .mu.m and/or greater than 300 .mu.m
and/or greater than 325 .mu.m and/or greater than 350 .mu.m and/or
greater than 375 .mu.m and/or greater than 400 .mu.m and/or greater
than 450 .mu.m and/or greater than 500 .mu.m and/or greater than
525 .mu.m as measured according to the Surface Height Test Method
described herein; [0095] b. a root mean square average surface
height value (Sq) of greater than 300 .mu.m and/or greater than 325
.mu.m and/or greater than 350 .mu.m and/or greater than 375 .mu.m
and/or greater than 400 .mu.m and/or greater than 450 .mu.m and/or
greater than 500 .mu.m and/or greater than 525 .mu.m and/or greater
than 575 .mu.m as measured according to the Surface Height Test
Method described herein; [0096] c. a height difference surface
height value (Sk) of greater than 825 .mu.m and/or greater than 875
and/or greater than 900 and/or greater than 925 and/or greater than
975 and/or greater than 1000 and/or greater than 1125 and/or
greater than 1150 and/or greater than 1200 and/or greater than 1250
and/or greater than 1300 and/or greater than 1350 and/or greater
than 1400 and/or greater than 1450 and/or greater than 1500 as
measured according to the Surface Height Test Method described
herein.
[0097] In one example, a textured fibrous structure void of
spunbond (i.e., not a textured spunbond/pulp/spunbond fibrous
structure), for example a textured coformed fibrous structure,
textured spunlaced fibrous structure, or textured airlaid fibrous
structure according to the present invention comprises at least one
surface comprising a plurality of deformations such that the
surface exhibits one or more of the following surface height
properties: [0098] a. an average absolute surface height value (Sa)
of greater than 85 .mu.m and/or greater than 90 .mu.m and/or
greater than 100 .mu.m and/or greater than 150 .mu.m and/or greater
than 200 .mu.m and/or greater than 250 .mu.m and/or greater than
275 .mu.m and/or greater than 300 .mu.m and/or greater than 325
.mu.m and/or greater than 350 .mu.m and/or greater than 375 .mu.m
and/or greater than 400 .mu.m and/or greater than 450 .mu.m and/or
greater than 500 .mu.m and/or greater than 525 .mu.m as measured
according to the Surface Height Test Method described herein;
[0099] b. a root mean square average surface height value (Sq) of
greater than 125 .mu.m and/or greater than 150 .mu.m and/or greater
than 200 .mu.m and/or greater than 250 .mu.m and/or greater than
300 .mu.m and/or greater than 325 .mu.m and/or greater than 350
.mu.m and/or greater than 375 .mu.m and/or greater than 400 .mu.m
and/or greater than 450 .mu.m and/or greater than 500 .mu.m and/or
greater than 525 .mu.m and/or greater than 575 .mu.m as measured
according to the Surface Height Test Method described herein;
[0100] c. a height difference surface height value (Sk) of greater
than 270 .mu.m and/or greater than 300 .mu.m and/or greater than
350 .mu.m and/or greater than 400 .mu.m and/or greater than 450
.mu.m and/or greater than 500 .mu.m and/or greater than 600 .mu.m
and/or greater than 700 .mu.m and/or greater than 825 .mu.m and/or
greater than 875 and/or greater than 900 and/or greater than 925
and/or greater than 975 and/or greater than 1000 and/or greater
than 1125 and/or greater than 1150 and/or greater than 1200 and/or
greater than 1250 and/or greater than 1300 and/or greater than 1350
and/or greater than 1400 and/or greater than 1450 and/or greater
than 1500 as measured according to the Surface Height Test Method
described herein.
[0101] In one example, a textured fibrous structure void of pulp,
for example a textured spunlaced fibrous structure according to the
present invention comprises at least one surface comprising a
plurality of deformations such that the surface exhibits one or
more of the following surface height properties: [0102] a. an
average absolute surface height value (Sa) of greater than 80 .mu.m
and/or greater than 82 .mu.m and/or greater than 85 .mu.m and/or
greater than 90 .mu.m and/or greater than 100 .mu.m and/or greater
than 150 .mu.m and/or greater than 200 .mu.m and/or greater than
250 .mu.m and/or greater than 275 .mu.m and/or greater than 300
.mu.m and/or greater than 325 .mu.m and/or greater than 350 .mu.m
and/or greater than 375 .mu.m and/or greater than 400 .mu.m and/or
greater than 450 .mu.m and/or greater than 500 .mu.m and/or greater
than 525 .mu.m as measured according to the Surface Height Test
Method described herein; [0103] b. a root mean square average
surface height value (Sq) of greater than 117 .mu.m and/or greater
than 120 .mu.m and/or greater than 125 .mu.m and/or greater than
150 .mu.m and/or greater than 200 .mu.m and/or greater than 250
.mu.m and/or greater than 300 .mu.m and/or greater than 325 .mu.m
and/or greater than 350 .mu.m and/or greater than 375 .mu.m and/or
greater than 400 .mu.m and/or greater than 450 .mu.m and/or greater
than 500 .mu.m and/or greater than 525 .mu.m and/or greater than
575 .mu.m as measured according to the Surface Height Test Method
described herein; [0104] c. a height difference surface height
value (Sk) of greater than 245 .mu.m and/or greater than 250 .mu.m
and/or greater than 300 .mu.m and/or greater than 350 .mu.m and/or
greater than 400 .mu.m and/or greater than 450 .mu.m and/or greater
than 500 .mu.m and/or greater than 600 .mu.m and/or greater than
700 .mu.m and/or greater than 825 .mu.m and/or greater than 875
and/or greater than 900 and/or greater than 925 and/or greater than
975 and/or greater than 1000 and/or greater than 1125 and/or
greater than 1150 and/or greater than 1200 and/or greater than 1250
and/or greater than 1300 and/or greater than 1350 and/or greater
than 1400 and/or greater than 1450 and/or greater than 1500 as
measured according to the Surface Height Test Method described
herein.
[0105] In one example, a textured fibrous structure void of
filaments, for example a textured airlaid fibrous structure, such
as a textured airlaid comprising a liquid composition, such as a
lotion, according to the present invention comprises at least one
surface comprising a plurality of deformations such that the
surface exhibits one or more of the following surface height
properties: [0106] a. an average absolute surface height value (Sa)
of greater than greater than 60 .mu.m and/or greater than 65 .mu.m
and/or greater than 70 .mu.m and/or greater than 75 .mu.m and/or
greater than 80 .mu.m and/or greater than 82 .mu.m and/or greater
than 85 .mu.m and/or greater than 90 .mu.m and/or greater than 100
.mu.m and/or greater than 150 .mu.m and/or greater than 200 .mu.m
and/or greater than 250 .mu.m and/or greater than 275 .mu.m and/or
greater than 300 .mu.m and/or greater than 325 .mu.m and/or greater
than 350 .mu.m and/or greater than 375 .mu.m and/or greater than
400 .mu.m and/or greater than 450 .mu.m and/or greater than 500
.mu.m and/or greater than 525 .mu.m as measured according to the
Surface Height Test Method described herein; [0107] b. a root mean
square average surface height value (Sq) of greater than 80 .mu.m
and/or greater than 90 .mu.m and/or greater than 100 .mu.m and/or
greater than 110 .mu.m and/or greater than 117 .mu.m and/or greater
than 120 .mu.m and/or greater than 125 .mu.m and/or greater than
150 .mu.m and/or greater than 200 .mu.m and/or greater than 250
.mu.m and/or greater than 300 .mu.m and/or greater than 325 .mu.m
and/or greater than 350 .mu.m and/or greater than 375 .mu.m and/or
greater than 400 .mu.m and/or greater than 450 .mu.m and/or greater
than 500 .mu.m and/or greater than 525 .mu.m and/or greater than
575 .mu.m as measured according to the Surface Height Test Method
described herein; [0108] c. a height difference surface height
value (Sk) of greater than 195 .mu.m and/or greater than 200 .mu.m
and/or greater than 225 .mu.m and/or greater than 245 .mu.m and/or
greater than 250 .mu.m and/or greater than 300 .mu.m and/or greater
than 350 .mu.m and/or greater than 400 .mu.m and/or greater than
450 .mu.m and/or greater than 500 .mu.m and/or greater than 600
.mu.m and/or greater than 700 .mu.m and/or greater than 825 .mu.m
and/or greater than 875 and/or greater than 900 and/or greater than
925 and/or greater than 975 and/or greater than 1000 and/or greater
than 1125 and/or greater than 1150 and/or greater than 1200 and/or
greater than 1250 and/or greater than 1300 and/or greater than 1350
and/or greater than 1400 and/or greater than 1450 and/or greater
than 1500 as measured according to the Surface Height Test Method
described herein.
[0109] In another example, the textured fibrous structures are made
on and the surface height properties and element characteristics
are achieved using a monoplanar collection device, such as a
resinous belt, alone or on a support fabric, rather than on a
multi-planar woven fabric.
[0110] The presence of the deformations on one or more surfaces of
the textured fibrous structures of the present invention are such
that surface height properties described herein of the textured
fibrous structures are produced.
[0111] Table 1 below shows surface height property values for
comparative examples of fibrous structures, some textured, and
inventive examples.
TABLE-US-00001 TABLE 1 Fibrous Sa Sq Sk Structure Type (.mu.m)
(.mu.m) (.mu.m) Inventive Spunlaced 318 - Side A 315.1 351.9 916.6
Sample 1 318 - Side A2 285.5 319.5 833.5 318 - Side B 301.6 338.7
888.7 318 - Side B2 234 270.1 717.2 Inventive Coformed 319 - Side A
544.7 613.2 1533.3 Sample 2 319 - Side A2 513.6 570.1 1471.4 319 -
Side B 483.3 537.4 1399.9 319 - Side B2 478.9 530.9 1368.3
Inventive Spunbond/Pulp/ 321 - Side A 340.8 382.5 1003.8 Sample 3
Spunbond 321 - Side A2 344.6 387.2 1019.1 321 - Side B 328.7 370
958.4 321 - Side B2 311.2 354.7 926.9 Inventive Airlaid 322 - Side
A 374.9 422.8 1119.6 Sample 4 322 - Side A2 387.8 436.5 1147.2 322
- Side B 377.4 426.6 1124.1 322 - Side B2 346.9 392.9 1029.9
Inventive Coformed Side A 422.5 473.6 1254.5 Sample 5 Side A2 385.6
435.2 1154 Side B 361 416.6 1114.9 Side B2 308.5 356.9 950.8
Inventive Coformed 301 - Side A 468.3 530.3 1386.8 Sample 6 301 -
Side A2 505.5 570.6 1511.1 301 - Side B 373.3 421.9 1098.6 301 -
Side B2 388.6 439.8 1129.8 Inventive Coformed 303 - Side A 395
441.6 1144.3 Sample 7 303 - Side A2 349.1 388.7 993 303 - Side B
390.8 440.9 1167.9 303 - Side B2 412.6 464 1218.1 Comparative
Spunbond/Pulp/ Side A 234.3 282.8 782 Sample 1 Spunbond Side A2
237.5 288.6 806.4 Side B 185.7 228.9 632.6 Side B2 235.7 287.4
791.3 Pampers .RTM. Spunlaced 318 - Flat - 79.2 115.4 234.9 (FIGS.
1A- Side A 1B) 318 - Flat - 79.5 113.3 242.7 Side B Huggies .RTM.
Coformed 319 - Flat - 64.8 83.4 207.7 Natural Care Side A 319 -
Flat - 83.7 109.5 267.9 Side B Arvell .RTM. Spunbond/Pulp/ 321 -
Flat - 43.4 55.8 139.3 Spunbond Side A 321 - Flat - 50.3 64.4 163.3
Side B 7th Gen .RTM. Airlaid 322 - Flat - 59.8 75.4 194 (FIGS. 2A-
Side A 2B) 322 - Flat - 54.3 68.5 176.1 Side B
[0112] In one example of the textured fibrous structure of the
present invention as shown in FIG. 5, the textured fibrous
structure 10, for example a textured fibrous structure comprising a
plurality of filaments and/or comprising a liquid composition, such
as a lotion, comprises a surface 12 and one or more objects 14
formed by an arrangement of discrete deformations, for example
protrusions 16, such as a flower pattern. The opposite surface of
this textured fibrous structure 10 comprises a plurality of
depressions (not shown) that correspond to the protrusions 16.
[0113] In another example of the textured fibrous structure of the
present invention as shown in FIG. 6, the textured fibrous
structure 10, for example a textured fibrous structure comprising a
plurality of filaments and/or comprising a liquid composition, such
as a lotion, comprises a surface 12 and one or more objects 14
formed by an arrangement of discrete deformations, for example
protrusions 16, such as a flower pattern, in this case a larger
flower pattern than that shown in FIG. 5. The opposite surface of
this textured fibrous structure 10 comprises a plurality of
depressions (not shown) that correspond to the protrusions 16.
[0114] In still another example of the textured fibrous structure
of the present invention as shown in FIG. 7 the textured fibrous
structure 10, for example a textured fibrous structure comprising a
plurality of filaments and/or comprising a liquid composition, such
as a lotion, comprises a surface 12 and one or more objects 14
formed by an arrangement of discrete deformations, for example
protrusions 16, such as a coin pattern made up of a center
deformation and four surrounding deformations.
[0115] As illustrated in FIGS. 5-7, the surface 12 of the textured
fibrous structures 10 of the present invention may comprise one or
more and/or two or more and/or three or more and/or four or more
groups (a group is more than 3 and/or more than 4 and/or more than
5 and/or more than 10 and/or more than 15 and/or more than 20
discrete deformations) of discrete deformations that exhibit
different surface height properties and/or exhibit different
element characteristics, such as element count (number of elements
in a group and/or total number of elements), area, perimeter,
length, angle, width, aspect ratio, perimeter to area ratio, and
inter-element distances for elements within a group and/or elements
in different groups and/or for all elements. In one example, a
group of deformations is different from another group of
deformations if they are discernible visually and/or mathematically
from one another based on surface height and/or element
characteristics, such as area. In another example, a group of
deformations if the average value of the surface height and/or the
element characteristic, for example area, is at least 10% and/or at
least 15% and/or at least 20% and/or at least 25% and/or at least
30% and/or at least 40% different from the average value of the
surface height of the groups of deformations and/or different from
the average value of the element characteristic of the groups of
deformations, such as area. A group of elements may exhibit a 10%
or less and/or 8% or less and/or 5% or less and/or 3% or less
deviation of an element characteristic, such as area, among the
elements within the group.
[0116] FIGS. 8-10 (Textured Fibrous Structures according to the
present invention) illustrate this concept. FIG. 8 corresponds to
the textured fibrous structure shown in FIG. 5 and clearly shows
three or more groups; namely three groups of discrete deformations
and thus elements that exhibit different element characteristics,
for example areas, such as non-constant areas of discrete
deformations between groups and in one example with respect to the
elements in general. For example, one group of discrete
deformations, the largest elements, exhibit an average area of
about 45 mm.sup.2, another group, the medium sized elements,
exhibit an average area of about 18 mm.sup.2 and the third group,
the smallest elements, exhibit an average area of about 3
mm.sup.2.
[0117] FIG. 9 corresponds to the textured fibrous structure shown
in FIG. 6 and clearly shows three or more groups; namely three
groups of discrete deformations and thus elements that exhibit
different element characteristics, for example areas. For example,
one group of discrete deformations, the largest elements, exhibit
an average area of about 100 mm.sup.2, another group, the medium
sized elements, exhibit an average area of about 40 mm.sup.2 and
the third group, the smallest elements, exhibit an average area of
about 9 mm.sup.2.
[0118] FIG. 10 corresponds to the textured fibrous structure shown
in FIG. 7 and appears to show three groups of discrete deformations
and thus elements that exhibit different element characteristics,
for example areas. However, upon review of the area profile and the
analysis image it is evident that an artifact of bridging is
occurring. One of skill in the art would recognize this bridging
effect and discount that apparent group of deformations (in this
case, the largest elements). Accordingly, it is clear that FIG. 10
shows two or more groups; namely two groups of discrete
deformations and thus elements that exhibit different element
characteristics, for example areas. For example, one group of
discrete deformations exhibit an average area of about 30 mm.sup.2,
and the other group exhibit an average area of about 19
mm.sup.2.
[0119] FIGS. 8-10 clearly illustrate that the examples of the
textured fibrous structure of the present invention shown therein
comprise at least one surface comprising greater than 10% and/or
greater than 15% and/or greater than 20% and/or greater than 25%
and/or greater than 30% and/or greater than 35% of elements that
exhibits an average area of greater than 10 mm.sup.2 and/or greater
than 15 mm.sup.2 and/or greater than 20 mm.sup.2 and/or greater
than 25 mm.sup.2 and/or greater than 30 mm.sup.2 as measured
according to the Element Characterization Test Method described
herein.
[0120] In addition to the areas of the elements shown in FIGS.
8-10, FIGS. 8-10 also show that the examples of the textured
fibrous structures of the present invention exhibit mean
inter-element distances of greater than 1.1 mm and/or greater than
1.2 mm and/or greater than 1.4 mm and/or greater than 1.5 mm and/or
greater than 1.7 mm and/or greater than 1.8 mm and/or greater than
2.0 mm and/or greater than 2.2 mm and/or greater than 2.5 mm and/or
greater than 2.75 mm and/or greater than 3.0 mm and mean
inter-element distance standard deviations of greater than 0.4
and/or greater than 0.5 and/or greater than 0.6 and/or greater than
0.7 and/or greater than 0.75 and/or greater than 0.8 and/or greater
than 0.9 and/or greater than 1.0 and/or greater than 1.1 and/or
greater than 1.2 as measured according to the Element
Characterization Test Method described herein.
[0121] In addition to the areas and inter-element distances, the
textured fibrous structures 10 of the present invention may
comprise a surface 12 comprising discrete deformations, for example
discrete protrusions 16, such that discrete deformations are
arranged and/or oriented such that three or more and/or four or
more and/or five or more different (greater than 10% and/or greater
than 15% and/or greater than 20% and/or greater than 25% difference
between angles) element angles (referenced as 20, 22, 24, and 26)
with respect to the MD, and/or groups of element angles with
respect to the MD are present (as shown in FIGS. 5-7) as measured
according to the Element Characterization Test Method described
herein.
[0122] In addition, the textured fibrous structures of the present
invention may comprise a surface comprising discrete deformations
such that discrete deformations exhibit element areas and element
perimeters such that the ratio of element perimeter to element area
is 1 or less and/or 0.9 or less and/or 0.8 or less and/or 0.7 or
less and/or 0.6 or less as measured according to the Element
Characterization Test Method described herein.
[0123] The texture fibrous structure of the present invention may
comprise a plurality of filaments and fibers commingled together,
for example as a coform textured fibrous structure.
[0124] At least one of the fibrous elements, for example filaments,
within the textured fibrous structure of the present invention may
comprise a thermoplastic polymer. The thermoplastic polymer, when
present, may be selected from the group consisting of: polyolefins,
polyesters, and mixtures thereof. In one example, the thermoplastic
polymer is a polyolefin, such as polypropylene and/or polyethylene.
In one example, the polyolefin is polypropylene.
[0125] The fibers, when present in the textured fibrous structures
of the present invention, may comprise pulp fibers, such as wood
pulp fibers.
[0126] The textured fibrous structures of the present invention may
comprise a plurality of filaments, a plurality of solid additives,
such as fibers, and a mixture of filaments and solid additives, for
example fibers, such as pulp fibers.
[0127] FIGS. 11-15 below are meant to show examples of different
configurations and/or structures that the textured fibrous
structures of the present invention may be produced in. The
plurality of deformations on the surface(s) of the textured fibrous
structures of the present invention are not explicitly shown in
FIGS. 11-15, but are considered to be present for purposes of this
application.
[0128] FIGS. 11 and 12 show schematic representations of an example
of a textured fibrous structure in accordance with the present
invention. As shown in FIGS. 11 and 12, the textured fibrous
structure 10 may be a co-formed fibrous structure. The textured
fibrous structure 10 comprises a plurality of filaments 28, such as
polypropylene filaments, and a plurality of solid additives, such
as wood pulp fibers 30. The filaments 28 may be randomly arranged
as a result of the process by which they are spun and/or formed
into the textured fibrous structure 10. The wood pulp fibers 30,
may be randomly dispersed throughout the textured fibrous structure
10 in the x-y plane. The wood pulp fibers 30 may be non-randomly
dispersed throughout the fibrous structure in the z-direction. In
one example (not shown), the wood pulp fibers 30 are present at a
higher concentration on one or more of the exterior, x-y plane
surfaces than within the fibrous structure along the
z-direction.
[0129] As shown in FIG. 13, another example of a fibrous structure
in accordance with the present invention is a layered textured
fibrous structure 10. The layered textured fibrous structure 10
comprises a first layer 32 comprising a plurality of filaments 28a,
such as polypropylene filaments, and a plurality of solid
additives, in this example, wood pulp fibers 30. The layered
textured fibrous structure 10 further comprises a second layer 34
comprising a plurality of filaments 28b, such as polypropylene
filaments. In one example, the first and second layers 32, 34,
respectively, are sharply defined zones of concentration of the
filaments and/or solid additives. The plurality of filaments 28b
may be deposited directly onto a surface of the first layer 32 to
form a layered textured fibrous structure that comprises the first
and second layers 32, 34, respectively.
[0130] Further, the layered textured fibrous structure 10 may
comprise a third layer 36, as shown in FIG. 13. The third layer 36
may comprise a plurality of filaments 28c, which may be the same or
different from the filaments 28b and/or 28a in the second 34 and/or
first 32 layers, respectively. As a result of the addition of the
third layer 36, the first layer 32 is positioned, for example
sandwiched, between the second layer 34 and the third layer 36. The
plurality of filaments 28c may be deposited directly onto a surface
of the first layer 32, opposite from the second layer 34, to form
the layered textured fibrous structure 10 that comprises the first,
second and third layers 32, 34, 36, respectively. The second and
third layers 34, 36 may function as a scrim material in the layered
textured fibrous structure 10.
[0131] As shown in FIG. 14, a cross-sectional schematic
representation of another example of a textured fibrous structure
in accordance with the present invention comprising a layered
textured fibrous structure 10 comprising a first layer 32, a second
layer 34 and optionally a third layer 36. The first layer 32
comprises a plurality of filaments 28a, such as polypropylene
filaments, and a plurality of solid additives, such as wood pulp
fibers 30. The second layer 34 may comprise any suitable filaments,
solid additives and/or polymeric films. In one example, the second
layer 34 comprises a plurality of filaments 28b. In one example,
the filaments 28b comprise a polymer selected from the group
consisting of: polysaccharides, polysaccharide derivatives,
polyvinylalcohol, polyvinylalcohol derivatives and mixtures
thereof.
[0132] In yet another example, a textured fibrous structure of the
present invention may comprise two outer layers consisting of 100%
by weight filaments and an inner layer consisting of 100% by weight
fibers.
[0133] In another example of a textured fibrous structure in
accordance with the present invention, instead of being layers of
fibrous structure 10, the material forming layers 32, 34, and 36,
may be in the form of plies wherein two or more of the plies may be
combined to form a textured fibrous structure. The plies may be
bonded together, such as by thermal bonding and/or adhesive
bonding, to form a multi-ply textured fibrous structure.
[0134] Another example of a textured fibrous structure of the
present invention in accordance with the present invention is shown
in FIG. 15. The textured fibrous structure 10 may comprise two or
more plies, wherein one ply 38 comprises any suitable textured
fibrous structure in accordance with the present invention, for
example textured fibrous structure 10 as shown and described in
FIGS. 11 and 12 and another ply 40 comprising any suitable fibrous
structure, for example a fibrous structure comprising filaments
28a, such as polypropylene filaments. The fibrous structure of ply
40 may be in the form of a net and/or mesh and/or other structure
that comprises pores that expose one or more portions of the
textured fibrous structure 10 to an external environment and/or at
least to liquids that may come into contact, at least initially,
with the fibrous structure of ply 40. In addition to ply 40, the
textured fibrous structure 10 may further comprise ply 42. Ply 42
may comprise a fibrous structure comprising filaments 28b, such as
polypropylene filaments, and may be the same or different from the
fibrous structure of ply 40.
[0135] Two or more of the plies 38, 40, and 42 may be bonded
together, such as by thermal bonding and/or adhesive bonding, to
form a multi-ply fibrous structure. After a bonding operation,
especially a thermal bonding operation, it may be difficult to
distinguish the plies of the textured fibrous structure 10 and the
textured fibrous structure 10 may visually and/or physically be a
similar to a layered fibrous structure in that one would have
difficulty separating the once individual plies from each other. In
one example, ply 38 may comprise a textured fibrous structure that
exhibits a basis weight of at least about 15 g/m.sup.2 and/or at
least about 20 g/m.sup.2 and/or at least about 25 g/m.sup.2 and/or
at least about 30 g/m.sup.2 up to about 120 g/m.sup.2 and/or 100
g/m.sup.2 and/or 80 g/m.sup.2 and/or 60 g/m.sup.2 and the plies 40
and 42, when present, independently and individually, may comprise
fibrous structures that exhibit basis weights of less than about 10
g/m.sup.2 and/or less than about 7 g/m.sup.2 and/or less than about
5 g/m.sup.2 and/or less than about 3 g/m.sup.2 and/or less than
about 2 g/m.sup.2 and/or to about 0 g/m.sup.2 and/or 0.5
g/m.sup.2.
[0136] Plies 40 and 42, when present, may help retain the solid
additives, in this case the wood pulp fibers 30, on and/or within
the textured fibrous structure of ply 38 thus reducing lint and/or
dust (as compared to a single-ply fibrous structure comprising the
textured fibrous structure of ply 38 without the plies 40 and 42)
resulting from the wood pulp fibers 30 becoming free from the
textured fibrous structure of ply 38.
[0137] The textured fibrous structures of the present invention may
comprise any suitable amount of filaments and any suitable amount
of solid additives. For example, the textured fibrous structures
may comprise from about 10% to about 70% and/or from about 20% to
about 60% and/or from about 30% to about 50% by dry weight of the
textured fibrous structure of filaments and from about 90% to about
30% and/or from about 80% to about 40% and/or from about 70% to
about 50% by dry weight of the textured fibrous structure of solid
additives, such as wood pulp fibers. In one example, the textured
fibrous structures of the present invention comprise filaments.
[0138] The filaments and solid additives of the present invention
may be present in the textured fibrous structures according to the
present invention at weight ratios of filaments to solid additives
of from at least about 1:1 and/or at least about 1:1.5 and/or at
least about 1:2 and/or at least about 1:2.5 and/or at least about
1:3 and/or at least about 1:4 and/or at least about 1:5 and/or at
least about 1:7 and/or at least about 1:10.
[0139] The textured fibrous structures of the present invention
and/or any sanitary tissue products comprising such fibrous
structures may be subjected to any post-processing operations such
as embossing operations, printing operations, tuft-generating
operations, thermal bonding operations, ultrasonic bonding
operations, perforating operations, surface treatment operations
such as application of lotions, silicones and/or other materials,
folding, and mixtures thereof.
[0140] Non-limiting examples of suitable polypropylenes for making
the filaments of the present invention are commercially available
from Lyondell-Basell and Exxon-Mobil.
[0141] Any hydrophobic or non-hydrophilic materials within the
fibrous structure, such as polypropylene filaments, may be surface
treated and/or melt treated with a hydrophilic modifier.
Non-limiting examples of surface treating hydrophilic modifiers
include surfactants, such as Triton X-100. Non-limiting examples of
melt treating hydrophilic modifiers that are added to the melt,
such as the polypropylene melt, prior to spinning filaments,
include hydrophilic modifying melt additives such as VW351 and/or
S-1416 commercially available from Polyvel, Inc. and Irgasurf
commercially available from Ciba. The hydrophilic modifier may be
associated with the hydrophobic or non-hydrophilic material at any
suitable level known in the art. In one example, the hydrophilic
modifier is associated with the hydrophobic or non-hydrophilic
material at a level of less than about 20% and/or less than about
15% and/or less than about 10% and/or less than about 5% and/or
less than about 3% to about 0% by dry weight of the hydrophobic or
non-hydrophilic material.
[0142] The textured fibrous structures of the present invention may
include optional additives, each, when present, at individual
levels of from about 0% and/or from about 0.01% and/or from about
0.1% and/or from about 1% and/or from about 2% to about 95% and/or
to about 80% and/or to about 50% and/or to about 30% and/or to
about 20% by dry weight of the fibrous structure. Non-limiting
examples of optional additives include permanent wet strength
agents, temporary wet strength agents, dry strength agents such as
carboxymethylcellulose and/or starch, softening agents, lint
reducing agents, opacity increasing agents, wetting agents, odor
absorbing agents, perfumes, temperature indicating agents, color
agents, dyes, osmotic materials, microbial growth detection agents,
antibacterial agents and mixtures thereof.
[0143] The textured fibrous structure of the present invention may
itself be a sanitary tissue product. It may be convolutedly wound
about a core to form a roll. It may be combined with one or more
other fibrous structures as a ply to form a multi-ply sanitary
tissue product. In one example, a co-formed fibrous structure of
the present invention may be convolutedly wound about a core to
form a roll of co-formed sanitary tissue product. The rolls of
sanitary tissue products may also be coreless.
[0144] The textured fibrous structures of the present invention may
exhibit a Liquid Absorptive Capacity of at least 2.5 g/g and/or at
least 4.0 g/g and/or at least 7 g/g and/or at least 12 g/g and/or
at least 13 g/g and/or at least 13.5 g/g and/or to about 30.0 g/g
and/or to about 20 g/g and/or to about 15.0 g/g as measured
according to the Liquid Absorptive Capacity Test Method described
herein.
[0145] The textured fibrous structures of the present invention may
exhibit a pore volume distribution such that at least 2% and/or at
least 9% and/or at least 10% and/or at least 12% and/or at least
17% and/or at least 18% and/or at least 28% and/or at least 32%
and/or at least 43% of the total pore volume present in the
textured fibrous structure exists in pores of radii of from 91
.mu.m to 140 .mu.m as measured by the Pore Volume Distribution Test
Method described herein.
[0146] The textured fibrous structures of the present invention may
exhibit a pore volume distribution such that at least 2% and/or at
least 9% and/or at least 10% and/or at least 12% and/or at least
17% and/or at least 18% and/or at least 20% and/or at least 28%
and/or at least 32% and/or at least 43% of the total pore volume
present in the textured fibrous structure exists in pores of radii
of from 91 .mu.m to 120 .mu.m and/or exhibit a pore volume
distribution such that less than 50% and/or less than 45% and/or
less than 40% and/or less than 38% and/or less than 35% and/or less
than 30% of the total pore volume present in the textured fibrous
structure exists in pores of radii of from 101 .mu.m to 200 .mu.m
as measured by the Pore Volume Distribution Test Method described
herein. In one example, the textured fibrous structures of the
present invention exhibit a pore volume distribution such that at
least 20% and/or at least 28% and/or at least 32% and/or at least
43% of the total pore volume present in the textured fibrous
structure exists in pores of radii of from 91 .mu.m to 120 .mu.m
and exhibit a pore volume distribution such that less than 40%
and/or less than 38% and/or less than 35% and/or less than 30% of
the total pore volume present in the textured fibrous structure
exists in pores of radii of from 101 .mu.m to 200 .mu.m as measured
by the Pore Volume Distribution Test Method described herein.
[0147] The textured fibrous structures of the present invention may
exhibit a pore volume distribution such that at least 2% and/or at
least 9% and/or at least 10% and/or at least 12% and/or at least
17% and/or at least 18% and/or at least 20% and/or at least 28%
and/or at least 32% and/or at least 43% of the total pore volume
present in the fibrous structure exists in pores of radii of from
91 .mu.m to 140 .mu.m and/or exhibit a pore volume distribution
such that less than 50% and/or less than 45% and/or less than 40%
and/or less than 38% and/or less than 35% and/or less than 30% of
the total pore volume present in the textured fibrous structure
exists in pores of radii of from 101 .mu.m to 200 .mu.m and/or
exhibit a pore volume distribution such that less than 50% and/or
less than 45% and/or less than 40% and/or less than 38% and/or less
than 35% and/or less than 30% of the total pore volume present in
the textured fibrous structure exists in pores of radii of from 121
.mu.m to 200 .mu.m as measured by the Pore Volume Distribution Test
Method described herein. In another example, the textured fibrous
structures of the present invention exhibit a pore volume
distribution such that at least 43% of the total pore volume
present in the textured fibrous structure exists in pores of radii
of from 91 .mu.m to 140 .mu.m and exhibit a pore volume
distribution less than 40% and/or less than 38% and/or less than
35% and/or less than 30% of the total pore volume present in the
textured fibrous structure exists in pores of radii of from 101
.mu.m to 200 .mu.m and exhibit a pore volume distribution less than
40% and/or less than 38% and/or less than 35% and/or less than 30%
of the total pore volume present in the fibrous structure exists in
pores of radii of from 121 .mu.m to 200 .mu.m as measured by the
Pore Volume Distribution Test Method described herein.
[0148] The textured fibrous structures of the present invention may
exhibit a pore volume distribution such that at least 2% and/or at
least 9% and/or at least 10% and/or at least 12% and/or at least
17% and/or at least 18% and/or at least 20% and/or at least 28%
and/or at least 32% and/or at least 43% of the total pore volume
present in the textured fibrous structure exists in pores of radii
of from 91 .mu.m to 140 .mu.m and/or exhibit a pore volume
distribution such that less than 50% and/or less than 45% and/or
less than 40% and/or less than 38% and/or less than 35% and/or less
than 30% of the total pore volume present in the textured fibrous
structure exists in pores of radii of from 101 .mu.m to 200 .mu.m
as measured by the Pore Volume Distribution Test Method described
herein. In another example, the textured fibrous structures of the
present invention exhibit a pore volume distribution such that at
least 43% of the total pore volume present in the textured fibrous
structure exists in pores of radii of from 91 .mu.m to 140 .mu.m
and exhibit a pore volume distribution less than 40% and/or less
than 38% and/or less than 35% and/or less than 30% of the total
pore volume present in the textured fibrous structure exists in
pores of radii of from 101 .mu.m to 200 .mu.m as measured by the
Pore Volume Distribution Test Method described herein.
[0149] The textured fibrous structure of the present invention may
exhibit at least a bi-modal pore volume distribution (i.e., the
pore volume distribution exhibits at least two modes).
[0150] The deformations on the surface(s) of the textured fibrous
structures of the present invention may provide the textured
fibrous structures with a different pressure mapping profile that
what has been achievable in the past as measured according to the
Pressure Mapping Test Method described herein.
Wipe
[0151] The textured fibrous structures, as described above, may be
utilized to form a wipe. "Wipe" may be a general term to describe a
piece of material, generally non-woven material, used in cleansing
hard surfaces, food, inanimate objects, toys and body parts. In
particular, many currently available wipes may be intended for the
cleansing of the perianal area after defecation. Other wipes may be
available for the cleansing of the face or other body parts.
Multiple wipes may be attached together by any suitable method to
form a mitt.
[0152] The material from which a wipe is made should be strong
enough to resist tearing during normal use, yet still provide
softness to the user's skin, such as a child's tender skin.
Additionally, the material should be at least capable of retaining
its form for the duration of the user's cleansing experience.
[0153] Wipes may be generally of sufficient dimension to allow for
convenient handling. Typically, the wipe may be cut and/or folded
to such dimensions as part of the manufacturing process. In some
instances, the wipe may be cut into individual portions so as to
provide separate wipes which are often stacked and interleaved in
consumer packaging. In other embodiments, the wipes may be in a web
form where the web has been slit and folded to a predetermined
width and provided with means (e.g., perforations) to allow
individual wipes to be separated from the web by a user. Suitably,
an individual wipe may have a length between about 100 mm and about
250 mm and a width between about 140 mm and about 250 mm. In one
embodiment, the wipe may be about 200 mm long and about 180 mm wide
and/or about 180 mm long and about 180 mm wide and/or about 170 mm
long and about 180 mm wide and/or about 160 mm long and about 175
mm wide. The material of the wipe may generally be soft and
flexible, potentially having a structured surface to enhance its
cleaning performance.
[0154] It is also within the scope of the present invention that
the wipe may be a laminate of two or more materials. Commercially
available laminates, or purposely built laminates would be within
the scope of the present invention. The laminated materials may be
joined or bonded together in any suitable fashion, such as, but not
limited to, ultrasonic bonding, adhesive, glue, fusion bonding,
heat bonding, thermal bonding and combinations thereof. In another
alternative embodiment of the present invention the wipe may be a
laminate comprising one or more layers of nonwoven materials and
one or more layers of film. Examples of such optional films,
include, but are not limited to, polyolefin films, such as,
polyethylene film. An illustrative, but non-limiting example of a
nonwoven material which is a laminate is a laminate of a 16 gsm
nonwoven polypropylene and a 0.8 mm 20 gsm polyethylene film.
[0155] The wipes may also be treated to improve the softness and
texture thereof by processes such as hydroentanglement or
spunlacing. The wipes may be subjected to various treatments, such
as, but not limited to, physical treatment, such as ring rolling,
as described in U.S. Pat. No. 5,143,679; structural elongation, as
described in U.S. Pat. No. 5,518,801; consolidation, as described
in U.S. Pat. Nos. 5,914,084, 6,114,263, 6,129,801 and 6,383,431;
stretch aperturing, as described in U.S. Pat. Nos. 5,628,097,
5,658,639 and 5,916,661; differential elongation, as described in
WO Publication No. 2003/0028165A1; and other solid state formation
technologies as described in U.S. Publication No. 2004/0131820A1
and U.S. Publication No. 2004/0265534A1 and zone activation and the
like; chemical treatment, such as, but not limited to, rendering
part or all of the substrate hydrophobic, and/or hydrophilic, and
the like; thermal treatment, such as, but not limited to, softening
of fibers by heating, thermal bonding and the like; and
combinations thereof.
[0156] Wet wipes, such as baby wipes for example, should be strong
enough when pre-moistened with a lotion to maintain integrity in
use, but also soft enough to give a pleasing and comfortable
tactile sensation to the user(s). In addition, wet wipes should
have sufficient absorbency and porosity to be effective in cleaning
the soiled skin of a user while at the same time providing
sufficient barrier to protect the user from contacting the soil.
Protecting the user from contacting the soil, which may be measured
according to the Soil Leak Through Test Method described herein,
creates unique "barrier" demands for fibrous structures that can
negatively affect both the fibrous structures' absorbency and
lotion release, which may be measured by the Lotion Release Test
Method described herein. Moreover, wet wipes should have absorbency
properties such that each wipe of a stack remains wet during
extended storage periods but yet at the same time easily releases
lotion during use.
[0157] The wipe may exhibit a pore volume distribution such that at
least 43% and/or at least 45% and/or at least 50% and/or at least
55% and/or at least 60% and/or at least 75% of the total pore
volume present in the fibrous structures exists in pores of radii
of from 91 .mu.m to about 140 .mu.m as determined by the Pore
Volume Distribution Test Method described herein
[0158] The wipe may exhibit a pore volume distribution such that at
least 30% and/or at least 40% and/or at least 50% and/or at least
55% and/or at least 60% and/or at least 75% of the total pore
volume present in the fibrous structures exists in pores of radii
of from about 121 .mu.m to about 200 .mu.m as determined by the
Pore Volume Distribution Test Method described herein
[0159] The wipe may exhibit a pore volume distribution such that at
least 50% and/or at least 55% and/or at least 60% and/or at least
75% of the total pore volume present in the fibrous structures
exists in pores of radii of from about 101 .mu.m to about 200 .mu.m
as determined by the Pore Volume Distribution Test Method described
herein
[0160] The wipe may exhibit a pore volume distribution such that at
least 30% and/or at least 40% and/or at least 50% and/or at least
55% and/or at least 60% and/or at least 75% of the total pore
volume present in the fibrous structures exists in pores of radii
of from about 121 .mu.m to about 200 .mu.m as determined by the
Pore Volume Distribution Test Method described herein and exhibit a
pore volume distribution such that at least 50% and/or at least 55%
and/or at least 60% and/or at least 75% of the total pore volume
present in the fibrous structures exists in pores of radii of from
about 101 .mu.m to about 200 .mu.m as determined by the Pore Volume
Distribution Test Method described herein
[0161] The wipe may exhibit a pore volume distribution such that at
least 30% and/or at least 40% and/or at least 50% and/or at least
55% and/or at least 60% and/or at least 75% of the total pore
volume present in the fibrous structures exists in pores of radii
of from about 121.mu.m to about 200 .mu.m as determined by the Pore
Volume Distribution Test Method described herein and exhibit a pore
volume distribution such that at least 50% and/or at least 55%
and/or at least 60% and/or at least 75% of the total pore volume
present in the fibrous structures exists in pores of radii of from
about 101 .mu.m to about 200 .mu.m as determined by the Pore Volume
Distribution Test Method described herein.
[0162] The wipe may have a basis weight of at least about 30
grams/m.sup.2 and/or at least about 35 grams/m.sup.2 and/or at
least about 40 grams/m.sup.2. In one example, the wipe may have a
basis weight of at least about 45 grams/m.sup.2. In another
example, the wipe basis weight may be less than about 100
grams/m.sup.2. In another example, wipes may have a basis weight
between about 45 grams/m.sup.2 and about 75 grams/m.sup.2, and in
yet another embodiment a basis weight between about 45
grams/m.sup.2 and about 65 grams/m.sup.2.
[0163] In another example of the present invention the wipe may be
biodegradable. For example the wipe could be made from a
biodegradable material such as a polyesteramide, or high wet
strength cellulose.
[0164] In one example of the present invention, the textured
fibrous structure comprises a pre-moistened wipe, such as a baby
wipe. A plurality of the pre-moistened wipes may be stacked one on
top of the other and may be contained in a container, such as a
plastic tub or a film wrapper. In one example, the stack of
pre-moistened wipes (typically about 40 to 80 wipes/stack) may
exhibit a height of from about 50 to about 300 mm and/or from about
75 to about 125 mm. The pre-moistened wipes may comprise a liquid
composition, such as a lotion. The pre-moistened wipes may be
stored long term in a stack in a liquid impervious container or
film pouch without all of the lotion draining from the top of the
stack to the bottom of the stack. The pre-moistened wipes may
exhibit a Liquid Absorptive Capacity of at least 2.5 g/g and/or at
least 4.0 g/g and/or at least 7 g/g and/or at least 12 g/g and/or
at least 13 g/g and/or at least 13.5 g/g and/or to about 30.0 g/g
and/or to about 20 g/g and/or to about 15.0 g/g as measured
according to the Liquid Absorptive Capacity Test Method described
herein.
[0165] In another example, the pre-moistened wipes may exhibit a
saturation loading (g liquid composition to g of dry wipe) of from
about 1.5 to about 6.0 g/g. The liquid composition may exhibit a
surface tension of from about 20 to about 35 and/or from about 28
to about 32 dynes/cm. The pre-moistened wipes may exhibit a dynamic
absorption time (DAT) from about 0.01 to about 0.4 and/or from
about 0.01 to about 0.2 and/or from about 0.03 to about 0.1 seconds
as measured according to the Dynamic Absorption Time Test Method
described herein.
[0166] In one example, the pre-moistened wipes are present in a
stack of pre-moistened wipes that exhibits a height of from about
50 to about 300 mm and/or from about 75 to about 200 mm and/or from
about 75 to about 125 mm, wherein the stack of pre-moistened wipes
exhibits a saturation gradient index of from about 1.0 to about 2.0
and/or from about 1.0 to about 1.7 and/or from about 1.0 to about
1.5.
[0167] The wipes may be saturation loaded with a liquid composition
to form a pre-moistened fibrous structure or wipe. The loading may
occur individually, or after the fibrous structures or wipes are
place in a stack, such as within a liquid impervious container or
packet. In one example, the pre-moistened wipes may be saturation
loaded with from about 1.5 g to about 6.0 g and/or from about 2.5 g
to about 4.0 g of liquid composition per g of wipe.
[0168] The wipes may be placed in the interior of a container,
which may be liquid impervious, such as a plastic tub or a sealable
packet, for storage and eventual sale to the consumer. The wipes
may be folded and stacked. The wipes of the present invention may
be folded in any of various known folding patterns, such as
C-folding, Z-folding and quarter-folding. Use of a Z-fold pattern
may enable a folded stack of wipes to be interleaved with
overlapping portions. Alternatively, the wipes may include a
continuous strip of material which has perforations between each
wipe and which may be arranged in a stack or wound into a roll for
dispensing, one after the other, from a container, which may be
liquid impervious.
[0169] The wipes may further comprise prints, which may provide
aesthetic appeal. Non-limiting examples of prints include figures,
patterns, letters, pictures and combinations thereof.
Method for Making a Textured Fibrous Structure
[0170] The textured fibrous structures of the present invention may
be made by subjecting any suitable fibrous structure, such as a
fibrous structure comprising a plurality of filaments, to a
deformation-creating process that creates a plurality of discrete
deformations into one or more of the surfaces of the fibrous
structure such that a textured fibrous structure according to the
present invention is formed. Non-limiting examples of suitable
fibrous structures that can be used as the starting material to
form the textured fibrous structures of the present invention
include, but are not limited to, coform fibrous structures,
meltblown fibrous structures, spunbond fibrous structures,
spunbond/pulp/spunbond fibrous structures, meltblown/pulp/meltblown
fibrous structures, spunlace fibrous structures, and airlaid
fibrous structures.
[0171] The deformations may be imparted to one or more surfaces of
the fibrous structure by passing the fibrous structure through a
nip formed by a rubber roll (heated--hot or unheated--cold) and a
patterned belt or patterned roll that comprises deflection conduits
into which portions of the rubber roll flow to create deformations
in the fibrous structure. The pressure in the nip must be
sufficient enough to form the deformations in at least one surface
of the fibrous structure such that a resulting textured fibrous
structure according to the present invention is formed. In another
example a steel roll (heated--hot) may be used in place of the
rubber roll. In still another example, a fibrous structure is
placed between a patterned plate, such as a metal plate, and a
rubber plate and pressed at a pressure of greater than 100 psi
and/or greater than 250 psi and/or greater than 400 psi and/or
greater than 500 psi and/or greater than 750 psi and/or greater
than 1000 psi and/or greater than 1250 psi and/or greater than 1400
psi. The patterned plate and/or rubber plate may be heated to a
temperature of greater than 60.degree. C. and/or greater than
75.degree. C. and/or greater than 100.degree. C. and/or greater
than 110.degree. C. and/or greater than 125.degree. C. and/or
greater than 135.degree. C. The fibrous structure may be subjected
to a preheating operation prior to entering the deformation
generating operation.
Non-Limiting Example of Processes for Making a Textured Fibrous
Structure of the Present Invention
Example 1--Textured Coformed Fibrous Structure
[0172] The following coform textured fibrous structure is
manufactured on a pilot line in a two-pass, direct forming process
as follows: 1) making an unconsolidated coformed core layer; 2)
depositing a first scrim layer on a first surface of the coformed
core layer; 3) depositing a second scrim layer on the other side of
the coformed core layer; 4) bonding the coformed core layer and
scrim layers construct to form a coformed fibrous structure; and 5)
subjecting the coformed fibrous structure to a deformation
generating operation to produce a textured coformed fibrous
structure.
[0173] 1. Making Coformed Core Layer--
[0174] A 21%:27.5%47.5%:4% blend, respectively, of PH835
polypropylene (LyondellBasell, London, UK): Metocene MF650W
polypropylene (LyondellBasell, London, UK): Metocene MF650X
(LyondellBasell, London, UK): White 412951 (Ampacet Corporation,
Tarrytown, N.Y.) whitening agent/opacifier is dry blended, to form
a melt blend. The melt blend is heated to about 405.degree. F.
through a melt extruder. A 15.5 inch wide Biax 12 row spinnerette
with 192 nozzles per cross-direction inch, commercially available
from Biax Fiberfilm Corporation, is utilized. 40 nozzles per
cross-direction inch of the 192 nozzles have a 0.018 inch inside
diameter melt outlet hole while the remaining nozzles are plugged,
i.e., there is no opening in the nozzle. Approximately 0.18 grams
per (open) hole per minute (ghm) of the melt blend is extruded from
the open nozzles to form meltblown filaments from the melt blend.
Approximately 415 SCFM of compressed air is heated such that the
air has a temperature of about 395.degree. F. at the spinnerette.
Approximately 500 g/minute of Golden Isle (from Georgia Pacific)
4825 semi-treated SSK pulp (Georgia-Pacific, Atlanta, Ga.) is
defibrated through a hammermill to form SSK wood pulp fibers.
Approximately 2100 SCFM Air at a temperature of about 80.degree. F.
and about 75% relative humidity (RH) is drawn into the hammermill.
The pulp is conveyed, for example as described in copending U.S.
Pat. App. Nos. 62/094,087 filed Dec. 19, 2014 and 62/170,176 filed
Jun. 3, 2015, using a motive air mass flow of approximately 1200
SCFM via two solid additive spreaders. The solid additive spreaders
turns the pulp fibers and distributes the pulp fibers in the
cross-direction such that the pulp fibers are injected into the
stream of meltblown filaments at a 45.degree. angle through two 4
inch.times.15 inch cross-direction (CD) slots. The pulp conveying
ductwork and geometry may be as described in copending U.S. Pat.
App. Ser. Nos. 62/170,169 and 62/170,172 both filed Jun. 3, 2015. A
forming box surrounds the area where the meltblown filaments and
pulp fibers are commingled. This forming box is designed to reduce
the amount of air allowed to enter or escape from this commingling
area. The forming box, for example may be as described in U.S. Pat.
App. Ser. Nos. 62/094,089 filed Dec. 19, 2014 and 62/170,179 filed
Jun. 3, 2015. A forming vacuum pulls air through a moving
collection surface, such as a non-patterned forming belt or
through-air-drying fabric, thus collecting and accumulating the
commingled meltblown filaments and pulp fibers to form a fibrous
structure batt. An example of such a fabric is Albany International
Electrotech F541-281. The forming vacuum level is adjusted to
prevent excessive air from escaping from the forming box. The
fibrous structure batt formed by this process comprises about 77%
by dry fibrous structure weight of pulp and about 23% by dry
fibrous structure weight of meltblown filaments. The line speed is
adjusted to accumulate the fiber/filament blend to reach the
desired basis weight. The unconsolidated fibrous structure batt is
considered the core layer for this example, and the core layer is
gathered on a storage roll for later unwinding.
[0175] 2. First Scrim Layer--
[0176] A 21%: 27.5%: 47.5%: 4% blend, respectively, of PH835
polypropylene (LyondellBasell, London, UK): Metocene MF650W
polypropylene (LyondellBasell, London, UK): PP3546 polypropylene
(ExxonMobil, Irving, Tex.): White 412951 whitening agent/opacifier
(Ampacet Corporation, Tarrytown, N.Y.). The resin blend is heated
to 400.degree. F. in a melt extruder. The melt extruder is used to
feed the heated resin blend to a 15.5 inch wide Biax 12 row
spinneret with 192 holes per cross-direction inch (Biax Fiberfilm
Corporation, Greenville, Wis.) having 8 holes of the 192 holes per
cross-direction inch with a 0.018 inch inside diameter melt outlet
hole while the remaining nozzles are plugged. The resin blend
throughput in the spinneret is 0.18 grams per (open) hole per
minute (ghm), i.e., 22.32 grams resin/minute through the spinneret.
Compressed attenuating air is supplied to the spinneret at a rate
of 426 SCFM, heated such that it is at a temperature of 395.degree.
F. at the spinneret. The attenuated filaments are water mist
quenched using 2 misting nozzles, one on each broad side of the
filament stream, each supplied with air at 35 psig and sufficient
water supply for a flow rate of 2.5 gallons/hour. Following mist
quenching, the filaments are directed to a first foraminous belt
supplied with vacuum, operating horizontally and carrying the
previously-formed coformed core layer (unwound from its storage
roll) and controlled to move at a machine direction speed of 92
feet/minute; the filaments are accumulated over the coformed core
layer on a first surface thereof to form the first scrim layer at a
basis weight of approximately 2 gsm.
[0177] 3. Second Scrim Layer--
[0178] A second scrim layer is formed by producing meltblown
filaments in the same manner as for the first scrim layer as
described above. Except the previously-made coformed core layer and
overlying first scrim layer are released from the first foraminous
belt, turned 90.degree. on a roller, and passed to a second
foraminous belt operating vertically (also supplied with vacuum and
moving at 92 feet/minute), to carry the coformed core layer and
overlying first scrim layer, with the first scrim layer in facing
contact with the second foraminous belt. The filaments for the
second scrim layer are directed toward the second foraminous belt
and the exposed coformed core layer surface, to directly form a
second scrim layer overlying the exposed coformed core layer
surface.
[0179] 4. Bonding--
[0180] Following assembly of the three layers first scrim
layer/coformed core layer/second scrim layer of the fibrous
structure as described above, they are conveyed to a nip between a
pair of calendar bonding rollers. One bonding roller, which is
heated to 250.degree. F. at its surface, has pattern of bonding
protrusions machined thereon having a bonding area of 6.2 percent.
As they pass through the nip, the layers are consolidated in the
z-direction and thermally bonded in the pattern to form a thermally
bonded coformed fibrous structure.
[0181] 5. Deformation Generating Operation--
[0182] The unconsolidated thermally bonded coformed fibrous
structure is then subjected to a deformation generating operation
that results in a plurality of deformations, for example
protrusions and/or depressions, being generated on one or more
surfaces of the thermally bonded coformed fibrous structure by
placing the thermally bonded coformed fibrous structure between a
patterned metal plate, for example one of the patterns shown in
FIGS. 5-7, and a rubber plate and pressed at a pressure of about
1500 psi wherein the plates are heated to a temperature of about
138.degree. C. for a time sufficient to generate deformations in
the surface(s) of the thermally bonded coformed fibrous structure
that results in a textured coformed fibrous structure according the
present invention.
Example 2--Textured Coformed Fibrous Structure
[0183] The following coform textured fibrous structure is
manufactured on a pilot line in a two-pass, direct forming process
as follows: 1) making a consolidated coformed core layer; 2)
depositing a first scrim layer on a first surface of the coformed
core layer; 3) depositing a second scrim layer on the other side of
the coformed core layer; 4) bonding the coformed core layer and
scrim layers construct to form a coformed fibrous structure; and 5)
subjecting the coformed fibrous structure to a deformation
generating operation to produce a textured coformed fibrous
structure.
[0184] 1. Making Coformed Core Layer--
[0185] A 21%:27.5%47.5%:4% blend, respectively, of PH835
polypropylene (LyondellBasell, London, UK): Metocene MF650W
polypropylene (LyondellBasell, London, UK): Metocene MF650X
(LyondellBasell, London, UK): White 412951 (Ampacet Corporation,
Tarrytown, N.Y.) whitening agent/opacifier is dry blended, to form
a melt blend. The melt blend is heated to about 405.degree. F.
through a melt extruder. A 15.5 inch wide Biax 12 row spinnerette
with 192 nozzles per cross-direction inch, commercially available
from Biax Fiberfilm Corporation, is utilized. 40 nozzles per
cross-direction inch of the 192 nozzles have a 0.018 inch inside
diameter melt outlet hole while the remaining nozzles are plugged,
i.e., there is no opening in the nozzle. Approximately 0.18 grams
per (open) hole per minute (ghm) of the melt blend is extruded from
the open nozzles to form meltblown filaments from the melt blend.
Approximately 415 SCFM of compressed air is heated such that the
air has a temperature of about 395.degree. F. at the spinnerette.
Approximately 500 g/minute of Golden Isle (from Georgia Pacific)
4825 semi-treated SSK pulp (Georgia-Pacific, Atlanta, Ga.) is
defibrated through a hammermill to form SSK wood pulp fibers.
Approximately 2100 SCFM Air at a temperature of about 80.degree. F.
and about 75% relative humidity (RH) is drawn into the hammermill.
The pulp is conveyed, for example as described in copending U.S.
Pat. App. Nos. 62/094,087 filed Dec. 19, 2014 and 62/170,176 filed
Jun. 3, 2015, using a motive air mass flow of approximately 1200
SCFM via two solid additive spreaders. The solid additive spreaders
turns the pulp fibers and distributes the pulp fibers in the
cross-direction such that the pulp fibers are injected into the
stream of meltblown filaments at a 45.degree. angle through two 4
inch.times.15 inch cross-direction (CD) slots. The pulp conveying
ductwork and geometry may be as described in copending U.S. Pat.
App. Ser. Nos. 62/170,169 and 62/170,172 both filed Jun. 3, 2015. A
forming box surrounds the area where the meltblown filaments and
pulp fibers are commingled. This forming box is designed to reduce
the amount of air allowed to enter or escape from this commingling
area. The forming box, for example may be as described in U.S. Pat.
App. Ser. Nos. 62/094,089 filed Dec. 19, 2014 and 62/170,179 filed
Jun. 3, 2015. A forming vacuum pulls air through a moving
collection surface, such as a non-patterned forming belt or
through-air-drying fabric, thus collecting and accumulating the
commingled meltblown filaments and pulp fibers to form a fibrous
structure batt. An example of such a fabric is Albany International
Electrotech F541-281. The forming vacuum level is adjusted to
prevent excessive air from escaping from the forming box. The
fibrous structure batt formed by this process comprises about 77%
by dry fibrous structure weight of pulp and about 23% by dry
fibrous structure weight of meltblown filaments. The line speed is
adjusted to accumulate the fiber/filament blend to reach the
desired basis weight. The fibrous structure batt while carried on
the fabric is then consolidated by passing it through a pair of
calender rollers under a pressure of 40 psi and at a temperature of
about 275.degree., forming a core layer, and the core layer is
gathered on a storage roll for later unwinding.
[0186] 2. First Scrim Layer--
[0187] A 21%: 27.5%: 47.5%: 4% blend, respectively, of PH835
polypropylene (LyondellBasell, London, UK): Metocene MF650W
polypropylene (LyondellBasell, London, UK): PP3546 polypropylene
(ExxonMobil, Irving, Tex.): White 412951 whitening agent/opacifier
(Ampacet Corporation, Tarrytown, N.Y.). The resin blend is heated
to 400.degree. F. in a melt extruder. The melt extruder is used to
feed the heated resin blend to a 15.5 inch wide Biax 12 row
spinneret with 192 holes per cross-direction inch (Biax Fiberfilm
Corporation, Greenville, Wis.) having 8 holes of the 192 holes per
cross-direction inch with a 0.018 inch inside diameter melt outlet
hole while the remaining nozzles are plugged. The resin blend
throughput in the spinneret is 0.18 grams per (open) hole per
minute (ghm), i.e., 22.32 grams resin/minute through the spinneret.
Compressed attenuating air is supplied to the spinneret at a rate
of 426 SCFM, heated such that it is at a temperature of 395.degree.
F. at the spinneret. The attenuated filaments are water mist
quenched using 2 misting nozzles, one on each broad side of the
filament stream, each supplied with air at 35 psig and sufficient
water supply for a flow rate of 2.5 gallons/hour. Following mist
quenching, the filaments are directed to a first foraminous belt
supplied with vacuum, operating horizontally and carrying the
previously-formed coformed core layer (unwound from its storage
roll) and controlled to move at a machine direction speed of 92
feet/minute; the filaments are accumulated over the coformed core
layer on a first surface thereof to form the first scrim layer at a
basis weight of approximately 2 gsm.
[0188] 3. Second Scrim Layer--
[0189] A second scrim layer is formed by producing meltblown
filaments in the same manner as for the first scrim layer as
described above. Except the previously-made coformed core layer and
overlying first scrim layer are released from the first foraminous
belt, turned 90.degree. on a roller, and passed to a second
foraminous belt operating vertically (also supplied with vacuum and
moving at 92 feet/minute), to carry the coformed core layer and
overlying first scrim layer, with the first scrim layer in facing
contact with the second foraminous belt. The filaments for the
second scrim layer are directed toward the second foraminous belt
and the exposed coformed core layer surface, to directly form a
second scrim layer overlying the exposed coformed core layer
surface.
[0190] 4. Bonding--
[0191] Following assembly of the three layers first scrim
layer/coformed core layer/second scrim layer of the fibrous
structure as described above, they are conveyed to a nip between a
pair of calendar bonding rollers. One bonding roller, which is
heated to 250.degree. F. at its surface, has pattern of bonding
protrusions machined thereon having a bonding area of 6.2 percent.
As they pass through the nip, the layers are consolidated in the
z-direction and thermally bonded in the pattern to form a thermally
bonded coformed fibrous structure.
[0192] 5. Deformation Generating Operation--
[0193] The consolidated thermally bonded coformed fibrous structure
is then subjected to a deformation generating operation that
results in a plurality of deformations, for example protrusions
and/or depressions, being generated on one or more surfaces of the
thermally bonded coformed fibrous structure by placing the
thermally bonded coformed fibrous structure between a patterned
metal plate, for example one of the patterns shown in FIGS. 5-7,
and a rubber plate and pressed at a pressure of about 1500 psi
wherein the plates are heated to a temperature of about 138.degree.
C. for a time sufficient to generate deformations in the surface(s)
of the thermally bonded coformed fibrous structure that results in
a textured coformed fibrous structure according the present
invention.
Example 3--Textured Coformed Fibrous Structure
[0194] The following coform textured fibrous structure is
manufactured on a pilot line in a two-pass, direct forming process
as follows: 1) making an unconsolidated coformed core layer; 2)
depositing a first scrim layer on a first surface of the coformed
core layer; 3) depositing a second scrim layer on the other side of
the coformed core layer; 4) bonding the coformed core layer and
scrim layers construct to form a coformed fibrous structure; and 5)
subjecting the coformed fibrous structure to a deformation
generating operation to produce a textured coformed fibrous
structure.
[0195] 1. Making Coformed Core Layer--
[0196] A 21%:27.5%47.5%:4% blend, respectively, of PH835
polypropylene (LyondellBasell, London, UK): Metocene MF650W
polypropylene (LyondellBasell, London, UK): Metocene MF650X
(LyondellBasell, London, UK): White 412951 (Ampacet Corporation,
Tarrytown, N.Y.) whitening agent/opacifier is dry blended, to form
a melt blend. The melt blend is heated to about 405.degree. F.
through a melt extruder. A 15.5 inch wide Biax 12 row spinnerette
with 192 nozzles per cross-direction inch, commercially available
from Biax Fiberfilm Corporation, is utilized. 40 nozzles per
cross-direction inch of the 192 nozzles have a 0.018 inch inside
diameter melt outlet hole while the remaining nozzles are plugged,
i.e., there is no opening in the nozzle. Approximately 0.18 grams
per (open) hole per minute (ghm) of the melt blend is extruded from
the open nozzles to form meltblown filaments from the melt blend.
Approximately 415 SCFM of compressed air is heated such that the
air has a temperature of about 395.degree. F. at the spinnerette.
Approximately 500 g/minute of Golden Isle (from Georgia Pacific)
4825 semi-treated SSK pulp (Georgia-Pacific, Atlanta, Ga.) is
defibrated through a hammermill to form SSK wood pulp fibers.
Approximately 2100 SCFM Air at a temperature of about 80.degree. F.
and about 75% relative humidity (RH) is drawn into the hammermill.
The pulp is conveyed, for example as described in copending U.S.
Pat. App. Nos. 62/094,087 filed Dec. 19, 2014 and 62/170,176 filed
Jun. 3, 2015, using a motive air mass flow of approximately 1200
SCFM via two solid additive spreaders. The solid additive spreaders
turns the pulp fibers and distributes the pulp fibers in the
cross-direction such that the pulp fibers are injected into the
stream of meltblown filaments at a 45.degree. angle through two 4
inch.times.15 inch cross-direction (CD) slots. The pulp conveying
ductwork and geometry may be as described in copending U.S. Pat.
App. Ser. Nos. 62/170,169 and 62/170,172 both filed Jun. 3, 2015. A
forming box surrounds the area where the meltblown filaments and
pulp fibers are commingled. This forming box is designed to reduce
the amount of air allowed to enter or escape from this commingling
area. The forming box, for example may be as described in U.S. Pat.
App. Ser. Nos. 62/094,089 filed Dec. 19, 2014 and 62/170,179 filed
Jun. 3, 2015. A forming vacuum pulls air through a moving
collection surface, such as a non-patterned forming belt or
through-air-drying fabric, thus collecting and accumulating the
commingled meltblown filaments and pulp fibers to form a fibrous
structure batt. An example of such a fabric is Albany International
Electrotech F541-281. The forming vacuum level is adjusted to
prevent excessive air from escaping from the forming box. The
fibrous structure batt formed by this process comprises about 77%
by dry fibrous structure weight of pulp and about 23% by dry
fibrous structure weight of meltblown filaments. The line speed is
adjusted to accumulate the fiber/filament blend to reach the
desired basis weight. The unconsolidated fibrous structure batt is
considered the core layer for this example, and the core layer is
gathered on a storage roll for later unwinding.
[0197] 2. First Scrim Layer--
[0198] A 21%: 27.5%: 47.5%: 4% blend, respectively, of PH835
polypropylene (LyondellBasell, London, UK): Metocene MF650W
polypropylene (LyondellBasell, London, UK): PP3546 polypropylene
(ExxonMobil, Irving, Tex.): White 412951 whitening agent/opacifier
(Ampacet Corporation, Tarrytown, N.Y.). The resin blend is heated
to 400.degree. F. in a melt extruder. The melt extruder is used to
feed the heated resin blend to a 15.5 inch wide Biax 12 row
spinneret with 192 holes per cross-direction inch (Biax Fiberfilm
Corporation, Greenville, Wis.) having 8 holes of the 192 holes per
cross-direction inch with a 0.018 inch inside diameter melt outlet
hole while the remaining nozzles are plugged. The resin blend
throughput in the spinneret is 0.18 grams per (open) hole per
minute (ghm), i.e., 22.32 grams resin/minute through the spinneret.
Compressed attenuating air is supplied to the spinneret at a rate
of 426 SCFM, heated such that it is at a temperature of 395.degree.
F. at the spinneret. The attenuated filaments are water mist
quenched using 2 misting nozzles, one on each broad side of the
filament stream, each supplied with air at 35 psig and sufficient
water supply for a flow rate of 2.5 gallons/hour. Following mist
quenching, the filaments are directed to a first foraminous belt
supplied with vacuum, operating horizontally and carrying the
previously-formed coformed core layer (unwound from its storage
roll) and controlled to move at a machine direction speed of 92
feet/minute; the filaments are accumulated over the coformed core
layer on a first surface thereof to form the first scrim layer at a
basis weight of approximately 2 gsm.
[0199] 3. Second Scrim Layer--
[0200] A second scrim layer is formed by producing meltblown
filaments in the same manner as for the first scrim layer as
described above. Except the previously-made coformed core layer and
overlying first scrim layer are released from the first foraminous
belt, turned 90.degree. on a roller, and passed to a second
foraminous belt operating vertically (also supplied with vacuum and
moving at 92 feet/minute), to carry the coformed core layer and
overlying first scrim layer, with the first scrim layer in facing
contact with the second foraminous belt. The filaments for the
second scrim layer are directed toward the second foraminous belt
and the exposed coformed core layer surface, to directly form a
second scrim layer overlying the exposed coformed core layer
surface.
[0201] 4. Bonding--
[0202] Following assembly of the three layers first scrim
layer/coformed core layer/second scrim layer of the fibrous
structure as described above, they are conveyed to a nip between a
pair of calendar bonding rollers. One bonding roller, which is
heated to 250.degree. F. at its surface, has pattern of bonding
protrusions machined thereon having a bonding area of 6.2 percent.
As they pass through the nip, the layers are consolidated in the
z-direction and thermally bonded in the pattern to form a thermally
bonded coformed fibrous structure.
[0203] 5. Deformation Generating Operation--
[0204] The unconsolidated thermally bonded coformed fibrous
structure is then subjected to a deformation generating operation
that results in a plurality of deformations, for example
protrusions and/or depressions, being generated on one or more
surfaces of the thermally bonded coformed fibrous structure by
placing the thermally bonded coformed fibrous structure between two
plates (Plate A and Plate B). In one example, Plate A has a texture
and Plate B is flat. Plate A and Plate B could be both made of
metal, or polymer, or one another, or other materials. Plate A and
Plate B could be both hot, or cold, or one another. In another
example, both Plate A and Plate B have textures. The textures of
Plate A and Plate B can be same or different. For the case that
both Plate A and Plate B have the same textures, the textures of
Plate A and Plate B could be aligned or be off from each other
during consolidation. Plate A and Plate B could be both made of
metal, or polymer, or one another, or other materials. Plate A and
Plate B could be both hot, or cold, or one another. The pattern on
Plate A and/or Plate B may be one of the patterns shown in FIGS.
5-7. A press is applied to the plates at a pressure of about 1500
psi wherein the plates are heated to a temperature of about
138.degree. C. for a time sufficient to generate deformations in
the surface(s) of the thermally bonded coformed fibrous structure
that results in a textured coformed fibrous structure according the
present invention.
Example 4--Textured Coformed Fibrous Structure
[0205] The following coform textured fibrous structure is
manufactured on a pilot line in a two-pass, direct forming process
as follows: 1) making a consolidated coformed core layer; 2)
depositing a first scrim layer on a first surface of the coformed
core layer; 3) depositing a second scrim layer on the other side of
the coformed core layer; 4) bonding the coformed core layer and
scrim layers construct to form a coformed fibrous structure; and 5)
subjecting the coformed fibrous structure to a deformation
generating operation to produce a textured coformed fibrous
structure.
[0206] 1. Making Coformed Core Layer--
[0207] A 21%:27.5%47.5%:4% blend, respectively, of PH835
polypropylene (LyondellBasell, London, UK): Metocene MF650W
polypropylene (LyondellBasell, London, UK): Metocene MF650X
(LyondellBasell, London, UK): White 412951 (Ampacet Corporation,
Tarrytown, N.Y.) whitening agent/opacifier is dry blended, to form
a melt blend. The melt blend is heated to about 405.degree. F.
through a melt extruder. A 15.5 inch wide Biax 12 row spinnerette
with 192 nozzles per cross-direction inch, commercially available
from Biax Fiberfilm Corporation, is utilized. 40 nozzles per
cross-direction inch of the 192 nozzles have a 0.018 inch inside
diameter melt outlet hole while the remaining nozzles are plugged,
i.e., there is no opening in the nozzle. Approximately 0.18 grams
per (open) hole per minute (ghm) of the melt blend is extruded from
the open nozzles to form meltblown filaments from the melt blend.
Approximately 415 SCFM of compressed air is heated such that the
air has a temperature of about 395.degree. F. at the spinnerette.
Approximately 500 g/minute of Golden Isle (from Georgia Pacific)
4825 semi-treated SSK pulp (Georgia-Pacific, Atlanta, Ga.) is
defibrated through a hammermill to form SSK wood pulp fibers.
Approximately 2100 SCFM Air at a temperature of about 80.degree. F.
and about 75% relative humidity (RH) is drawn into the hammermill.
The pulp is conveyed, for example as described in copending U.S.
Pat. App. Nos. 62/094,087 filed Dec. 19, 2014 and 62/170,176 filed
Jun. 3, 2015, using a motive air mass flow of approximately 1200
SCFM via two solid additive spreaders. The solid additive spreaders
turns the pulp fibers and distributes the pulp fibers in the
cross-direction such that the pulp fibers are injected into the
stream of meltblown filaments at a 45.degree. angle through two 4
inch.times.15 inch cross-direction (CD) slots. The pulp conveying
ductwork and geometry may be as described in copending U.S. Pat.
App. Ser. Nos. 62/170,169 and 62/170,172 both filed Jun. 3, 2015. A
forming box surrounds the area where the meltblown filaments and
pulp fibers are commingled. This forming box is designed to reduce
the amount of air allowed to enter or escape from this commingling
area. The forming box, for example may be as described in U.S. Pat.
App. Ser. Nos. 62/094,089 filed Dec. 19, 2014 and 62/170,179 filed
Jun. 3, 2015. A forming vacuum pulls air through a moving
collection surface, such as a non-patterned forming belt or
through-air-drying fabric, thus collecting and accumulating the
commingled meltblown filaments and pulp fibers to form a fibrous
structure batt. An example of such a fabric is Albany International
Electrotech F541-281. The forming vacuum level is adjusted to
prevent excessive air from escaping from the forming box. The
fibrous structure batt formed by this process comprises about 77%
by dry fibrous structure weight of pulp and about 23% by dry
fibrous structure weight of meltblown filaments. The line speed is
adjusted to accumulate the fiber/filament blend to reach the
desired basis weight. The fibrous structure batt while carried on
the fabric is then consolidated by passing it through a pair of
calender rollers under a pressure of 40 psi and at a temperature of
about 275.degree., forming a core layer, and the core layer is
gathered on a storage roll for later unwinding.
[0208] 2. First Scrim Layer--
[0209] A 21%: 27.5%: 47.5%: 4% blend, respectively, of PH835
polypropylene (LyondellBasell, London, UK): Metocene MF650W
polypropylene (LyondellBasell, London, UK): PP3546 polypropylene
(ExxonMobil, Irving, Tex.): White 412951 whitening agent/opacifier
(Ampacet Corporation, Tarrytown, N.Y.). The resin blend is heated
to 400.degree. F. in a melt extruder. The melt extruder is used to
feed the heated resin blend to a 15.5 inch wide Biax 12 row
spinneret with 192 holes per cross-direction inch (Biax Fiberfilm
Corporation, Greenville, Wis.) having 8 holes of the 192 holes per
cross-direction inch with a 0.018 inch inside diameter melt outlet
hole while the remaining nozzles are plugged. The resin blend
throughput in the spinneret is 0.18 grams per (open) hole per
minute (ghm), i.e., 22.32 grams resin/minute through the spinneret.
Compressed attenuating air is supplied to the spinneret at a rate
of 426 SCFM, heated such that it is at a temperature of 395.degree.
F. at the spinneret. The attenuated filaments are water mist
quenched using 2 misting nozzles, one on each broad side of the
filament stream, each supplied with air at 35 psig and sufficient
water supply for a flow rate of 2.5 gallons/hour. Following mist
quenching, the filaments are directed to a first foraminous belt
supplied with vacuum, operating horizontally and carrying the
previously-formed coformed core layer (unwound from its storage
roll) and controlled to move at a machine direction speed of 92
feet/minute; the filaments are accumulated over the coformed core
layer on a first surface thereof to form the first scrim layer at a
basis weight of approximately 2 gsm.
[0210] 3. Second Scrim Layer--
[0211] A second scrim layer is formed by producing meltblown
filaments in the same manner as for the first scrim layer as
described above. Except the previously-made coformed core layer and
overlying first scrim layer are released from the first foraminous
belt, turned 90.degree. on a roller, and passed to a second
foraminous belt operating vertically (also supplied with vacuum and
moving at 92 feet/minute), to carry the coformed core layer and
overlying first scrim layer, with the first scrim layer in facing
contact with the second foraminous belt. The filaments for the
second scrim layer are directed toward the second foraminous belt
and the exposed coformed core layer surface, to directly form a
second scrim layer overlying the exposed coformed core layer
surface.
[0212] 4. Bonding--
[0213] Following assembly of the three layers first scrim
layer/coformed core layer/second scrim layer of the fibrous
structure as described above, they are conveyed to a nip between a
pair of calendar bonding rollers. One bonding roller, which is
heated to 250.degree. F. at its surface, has pattern of bonding
protrusions machined thereon having a bonding area of 6.2 percent.
As they pass through the nip, the layers are consolidated in the
z-direction and thermally bonded in the pattern to form a thermally
bonded coformed fibrous structure.
[0214] 5. Deformation Generating Operation--
[0215] The consolidated thermally bonded coformed fibrous structure
is then subjected to a deformation generating operation that
results in a plurality of deformations, for example protrusions
and/or depressions, being generated on one or more surfaces of the
thermally bonded coformed fibrous structure by placing the
thermally bonded coformed fibrous structure between two plates
(Plate A and Plate B). In one example, Plate A has a texture and
Plate B is flat. Plate A and Plate B could be both made of metal,
or polymer, or one another, or other materials. Plate A and Plate B
could be both hot, or cold, or one another. In another example,
both Plate A and Plate B have textures. The textures of Plate A and
Plate B can be same or different. For the case that both Plate A
and Plate B have the same textures, the textures of Plate A and
Plate B could be aligned or be off from each other during
consolidation. Plate A and Plate B could be both made of metal, or
polymer, or one another, or other materials. Plate A and Plate B
could be both hot, or cold, or one another. The pattern on Plate A
and/or Plate B may be one of the patterns shown in FIGS. 5-7. A
press is applied to the plates at a pressure of about 1500 psi
wherein the plates are heated to a temperature of about 138.degree.
C. for a time sufficient to generate deformations in the surface(s)
of the thermally bonded coformed fibrous structure that results in
a textured coformed fibrous structure according the present
invention.
Example 5--Textured Airlaid Fibrous Structure
[0216] An airlaid fibrous structure may be made by any suitable
airlaying process, for example by depositing individual fibers on a
formaminous surface via an airlaid device. These fibers can
include, but are not limited to traditional pulp fibers, staple
fibers, thermoplastic, and bicomponent fibers. After the individual
fibers are laid on the foraminous surface they are bound together
by any suitable means. The application and subsequent drying of
liquid latex, for example, is used in the production of Latex
Bonded Air Laid (LBAL) fibrous structures. Thermal bonding of the
fibrous structure via heat and pressure consolidating thermoplastic
fibers laid down in the beginning of the process creates Thermal
Bonded Air Laid (TBAL) fibrous structures. A combination of the
LBAL and TBAL processes creates Multi-Bonded Air Laid (MBAL)
fibrous structures.
[0217] The airlaid fibrous structure is then subjected to a
deformation generating operation that results in a plurality of
deformations, for example protrusions and/or depressions, being
generated on one or more surfaces of the airlaid fibrous structure
by placing the airlaid fibrous structure between a patterned metal
plate, for example one of the patterns shown in FIGS. 5-7, and a
rubber plate and pressed at a pressure of about 1500 psi wherein
the plates are heated to a temperature of about 138.degree. C. for
a time sufficient to generate deformations in the surface(s) of the
airlaid fibrous structure that results in a textured airlaid
fibrous structure according the present invention.
Example 6--Textured Spunlaced Fibrous Structure
[0218] A spunlaced fibrous structure may be made by any suitable
spunlacing process, for example by mixing staple fibers. The staple
fibers are formed into a web of a desired basis weight by using
carding technology well known in the industry, for example a Double
Excelle Vario three-doffer card from NSC Nonwoven, 59336 TOURCOING
CEDEX, France. The carded webs are then consolidated by using
hydroentanglement technology well known in the industry, for
example a JETlace.RTM.3000 from Rieter Perfojet (F-38330
Montbonnot--France) with a working width of 500 mm, with or without
hydromolding. The hydroentanglement system has a pre-wetting
conveyor and three cylinders with two injectors each. In total
three injectors (two on the first cylinder and one on the second
cylinder) are used for consolidation and strength generation. Each
jet is equipped with 120 micron strips with 42 holes/inch. The webs
are dried by using through air drying technology well known in the
industry, for example a PERFOdry3000 with a roll diameter of 2000
mm from Rieter Perfojet, to form a spunlaced fibrous structure.
[0219] The spunlaced fibrous structure is then subjected to a
deformation generating operation that results in a plurality of
deformations, for example protrusions and/or depressions, being
generated on one or more surfaces of the spunlaced fibrous
structure by placing the spunlaced fibrous structure between a
patterned metal plate, for example one of the patterns shown in
FIGS. 5-7, and a rubber plate and pressed at a pressure of about
1500 psi wherein the plates are heated to a temperature of about
138.degree. C. for a time sufficient to generate deformations in
the surface(s) of the spunlaced fibrous structure that results in a
textured spunlaced fibrous structure according the present
invention.
Example 7--Textured Spunbond/Pulp/Spunbond Fibrous Structure
[0220] A spunbond fibrous structure may be made by any suitable
spunbonding process, for example by spinning a spunbond web onto a
forming fabric. Pulp may be deposited onto the spunbond web after
spinning the spunbond web and/or during spinning of the spunond
web. One or more additional webs, for example spunbond and/or
meltblown webs, may be added to the spunbond/pulp structure by any
suitable spunbond and/or meltblown process to sandwich the pulp
between the first spunbond web and the additional web to form a
spunbond/pulp/spunbond fibrous structure for example. The
spunbond/pulp/spunbond fibrous structure may be thermally bonded by
any suitable thermal bonding process and any suitable thermal
bonding pattern.
[0221] The spunbond/pulp/spunbond fibrous structure is then
subjected to a deformation generating operation that results in a
plurality of deformations, for example protrusions and/or
depressions, being generated on one or more surfaces of the
spunbond/pulp/spunbond fibrous structure by placing the
spunbond/pulp/spunbond fibrous structure between a patterned metal
plate, for example one of the patterns shown in FIGS. 5-7, and a
rubber plate and pressed at a pressure of about 1500 psi wherein
the plates are heated to a temperature of about 138.degree. C. for
a time sufficient to generate deformations in the surface(s) of the
spunbond/pulp/spunbond fibrous structure that results in a textured
spunbond/pulp/spunbond fibrous structure according the present
invention.
Example 8--Pre-Moistened Wipe
[0222] A pre-moistened wipe according to the present invention is
prepared as follows. A textured fibrous structure of the present
invention, for example a textured fibrous structure according to
Examples 1 to 7, of about 44 g/m.sup.2 is saturation loaded with a
liquid composition according to the present invention to an average
saturation loading of about 358% of the basis weight of the wipe.
The wipes are then Z-folded and placed in a stack to a height of
about 82 mm.
Example 9--Pre-Moistened Wipe
[0223] A pre-moistened wipe according to the present invention is
prepared as follows. A textured fibrous structure of the present
invention, for example a textured fibrous structure according to
Examples 1 to 7, of about 61 g/m.sup.2 is saturation loaded with a
liquid composition according to the present invention to an average
saturation loading of about 347% of the basis weight of the wipe.
The wipes are then Z-folded and placed in a stack to a height of
about 82 mm.
Example 10--Pre-Moistened Wipe
[0224] A pre-moistened wipe according to the present invention is
prepared as follows. A textured fibrous structure of the present
invention, for example a textured fibrous structure according to
Examples 1 to 7, of about 65 g/m.sup.2 is saturation loaded with a
liquid composition according to the present invention to an average
saturation loading of about 347% of the basis weight of the wipe.
The wipes are then Z-folded and placed in a stack to a height of
about 82 mm.
Test Methods
[0225] Unless otherwise indicated, all tests described herein
including those described under the Definitions section and the
following test methods are conducted on samples that have been
conditioned in a conditioned room at a temperature of 23.degree.
C..+-.2.2.degree. C. and a relative humidity of 50%.+-.10% for 24
hours prior to the test. All tests are conducted in such
conditioned room.
[0226] For the dry test methods described herein (Liquid Absorptive
Capacity, Pore Volume Distribution, Basis Weight, and Dynamic
Absorption Time), if the fibrous structure or wipe comprises a
liquid composition such that the fibrous structure or wipe exhibits
a moisture level of about 100% or greater by weight of the fibrous
structure or wipe, then the following pre-conditioning procedure
needs to be performed on the fibrous structure or wipe before
testing. If the fibrous structure or wipe comprises a liquid
composition such that the fibrous structure or wipe exhibits a
moisture level of less than about 100% by weight but greater than
about 10% by weight of the fibrous structure or wipe, dry the
fibrous structure or wipe in an oven at 85.degree. C. until the
fibrous structure or wipe contains less than 3% moisture by weight
of the fibrous structure or wipe prior to completing the dry test
methods.
[0227] To pre-condition a fibrous structure or wipe comprising a
moisture level of about 100% or greater by weight of the fibrous
structure or wipe use the following procedure. Fully saturate the
fibrous structure or wipe by immersing the fibrous structure or
wipe sequentially in 2 L of fresh distilled water in each of 5
buckets, where the water is at a temperature of 23.degree.
C..+-.2.2.degree. C. Gently, agitate the fibrous structure or wipe
in the water by moving the fibrous structure or wipe from one side
of each bucket to the other at least 5 times, but no more than 10
times for 20 seconds in each of the 5 buckets. Remove the fibrous
structure or wipe and then place horizontally in an oven at
85.degree. C. until the fibrous structure or wipe contains less
than 3% moisture by weight of the fibrous structure or wipe. After
the fibrous structure or wipe exhibits less than 3% moisture,
remove from the oven and allow the fibrous structure or wipe to
equilibrate to about 23.degree. C..+-.2.2.degree. C. and a relative
humidity of 50%.+-.10% for 24 hours prior to the testing. Care
needs to be taken to ensure that the fibrous structure and/or wipe
is not compressed.
[0228] For the wet test methods described herein (Soil Leak
Through, CD Wet Initial Tensile Strength, Lotion Release,
Saturation Loading, and Saturation Gradient Index), if the fibrous
structure or wipe comprises a moisture level of 0% to less than
about 100% by weight of the fibrous structure or wipe, then the
following pre-conditioning procedure needs to be performed on the
fibrous structure or wipe prior to testing. If the fibrous
structure or wipe comprises a moisture level of about 100% or
greater, then the following pre-conditioning procedure is not
performed on the fibrous structure or wipe.
[0229] To pre-condition a fibrous structure or wipe comprising a
moisture level of 0% to less than about 100% by weight of the
fibrous structure or wipe, add an amount of distilled water to the
fibrous structure or wipe to achieve a 3.5 g/g saturation loading
on the fibrous structure or wipe.
[0230] After the fibrous structure or wipe is saturation loaded to
a 3.5 g/g saturation loading, allow the fibrous structure or wipe
to equilibrate to about 23.degree. C..+-.2.2.degree. C. and a
relative humidity of 50%.+-.10% for 24 hours prior to the testing.
Care needs to be taken to ensure that the fibrous structure and/or
wipe is not compressed.
Surface Height Test/Element Characterization Test Method
[0231] Substrate surface Sa, Sq and Sk parameters, pattern element
dimension and inter-element distance measurements are obtained
using a GFM MikroCAD Premium instrument commercially available from
GFMesstechnik GmbH, Teltow/Berlin, Germany, or equivalent. The
system includes the following main components: a) a Digital Light
Processing (DLP) projector with direct digital controlled
micro-mirrors; b) a CCD camera with at least a 1600.times.1200
pixel resolution; c) projection optics adapted to a measuring area
of at least 60 mm.times.45 mm; d) recording optics adapted to a
measuring area of 60 mm.times.45 mm; e) a table tripod based on a
small hard stone plate; f) a blue LED light source; g) a measuring,
control, and evaluation computer running ODSCAD software (version
6.2, or equivalent); and h) calibration plates for lateral (x-y)
and vertical (z) calibration available from the vendor.
[0232] The GFM MikroCAD Premium system measures the surface height
of a sample using the digital micro-mirror pattern fringe
projection technique. The result of the analysis is a map of
surface height (z-directional or z-axis) versus displacement in the
x-y plane. The system has a field of view of 60.times.45 mm with an
x-y pixel resolution of approximately 40 microns. The height
resolution is set at 0.5 micron/count, with a height range of +/-15
mm. All testing is performed in a conditioned room maintained at
about 23.+-.2.degree. C. and about 50.+-.2% relative humidity.
[0233] To obtain the samples to be measured, open a new package of
wet wipes and remove the entire stack from the package. Discard the
first 5 wipes from the top and bottom of the stack, and then remove
2 wipe samples from the top, middle and bottom of the stack, for a
total of 6 wipe samples to be analyzed per package. A total of
three packages should be measured, for a total of 18 samples. Lay
all of the samples out flat and allow them to completely dry prior
to testing.
[0234] Calibrate the instrument according to manufacturer's
specifications using the calibration plates for lateral (x-y axis)
and vertical (z axis) available from the vendor.
[0235] Place specimen on the table beneath the camera. Center the
specimen within the camera field of view, so that only the specimen
surface is visible in the image. Place a steel frame (100 mm
square, 1.5 mm thick with an opening 70 mm square) on the sample to
ensure the specimen lays flat with minimal wrinkles, and still
allows for an unobstructed access to the surface area being
scanned.
[0236] Collect a height image (z-direction) of the specimen by
following the instrument manufacturer's recommended measurement
procedures. Select the Technical Surface/Standard measurement
program with the following operating parameters: Utilization of
fast picture recording with a 3 frame delay. Dual phaseshifts are
used with 1) 16 pixel stripe width with a picture count of 12 and
2) 32 pixel stripe width with a picture count of 8. A full Graycode
starting with pixel 2 and ending with pixel 512. No filtering or
pre-filtering options should be utilized. After selection of the
measurement program, continue to follow the instrument
manufacturer's recommended procedures for focusing the measurement
system and performing the brightness adjustment. Perform the 3D
measurement then save the height image and camera image files.
[0237] a. Sa, Sq and Sk Measurements:
[0238] Sa and Sq are described in ISO 25178-2:2012. Sa is the
average of the absolute values of the profile heights of the
roughness surface, and Sq is the root mean square of the profile
heights of the roughness surface. The parameter Sk is derived from
the Areal Material Ratio (Abbott-Firestone) curve described in ISO
13565-2:1996 standard extrapolated to surfaces, it is the
cumulative curve of the surface height distribution histogram
versus the range of surface heights. The Core Roughness Depth, Sk,
is the height difference between the material ratios Mr1 and Mr2 as
read off of the Areal Material Ratio curve. Mr1, set to 10%, is the
material ratio which separates the protruding peaks from the core
roughness region. Mr2, set to 90%, is the material ratio which
separates the deep valleys from the core roughness region.
[0239] Load the height image into the analysis portion of the
software via the clipboard. The following filtering procedure is
then performed on each image: 1) removal of invalid points; 2)
3.times.3 pixel median filter to remove noise. Open the window to
calculate surface roughness parameters. Set the wavelength limit
for the Gaussian high pass filter to 25 mm to filter out large
scale waviness in the sample. Calculate the roughness parameters
using only a planar automatic alignment and Gaussian high pass
areal filter with a repeat number of 1. Record the surface
roughness values for Sa, Sq and Sk to the nearest 0.1 .mu.m. Save a
copy of the filtered roughness image. Repeat this procedure for the
remaining replicate samples. Average together the 18 replicate Sa,
Sq and Sk measures and report these values to the nearest 0.1
.mu.m.
[0240] b. Pattern Element Dimension Measurements
[0241] The pattern element dimension measurements are obtained by
analysis of a binary image where all of the regions in the filtered
roughness image above the threshold height value are black and
those below are white. To generate the binary image, first open the
filtered roughness image, which was produced by taking the original
height image through the following filtering/flattening procedure:
1) removal of invalid points; 2) 3.times.3 pixel median filter to
remove noise; 3) planar alignment; and 4) Gaussian high pass areal
filter with a wavelength limit of 25 mm. Next, open the histogram
of the image and identify the 50.sup.th percentile height from the
cumulative histogram. This is the height threshold for the pattern
element dimension analysis.
[0242] One skilled in the art will recognize that there are various
methods to obtain a binary image where the regions in the filtered
roughness image above the threshold height value are black and
those below are white. One such method is to save a grayscale image
in the ODSCAD software where the heights below the threshold value
are black and those above are shades of gray. This is accomplished
by displaying the height image using the grayscale color map and
then manually setting the minimum z-scale value to the threshold
height value (50.sup.th percentile height). This step produces an
image where the height values below the 50.sup.th percentile are
black, enabling them to be thresheld out in a later image
processing step. Export and save this image as a JPEG for further
image analysis.
[0243] To complete the generation of the binary image, and analyze
the pattern element dimensions, open the saved JPEG file of the
grayscale height image in ImageJ software (v. 1.47 or equivalent,
National Institute of Health, USA). For this analysis the
resolution of the image should be 16.5 pixels per mm, or 0.0606 mm
per pixel. If the image is at a higher resolution, resize the
number of pixels in the image to obtain this resolution, if the
image is at a lower resolution make adjustments in the step where
the JPEG image was generated to obtain a higher resolution image,
and then resize the image to the correct resolution. Once the
appropriate resolution has been obtained, set the scale of the
image. If necessary, crop the image so that it only contains the 60
mm.times.45 mm field of view from the height image.
[0244] Convert the scaled and cropped image to 8-bit grayscale,
display the image histogram and determine the graylevel value
nearest to the 50.sup.th percentile from a cumulative histogram.
Threshold the image at the 50.sup.th percentile graylevel (GL)
value to generate a binary image. This step produces a binary image
thresheld at the 50.sup.th percentile of the height distribution,
which separates the black pixels, representing the areas below the
50.sup.th percentile height, from the gray pixels above that
height. Initially, the binary image may display the regions above
the height threshold as white (GL value of 0). If so, invert the
image so that the pattern elements above the threshold height will
appear as black (GL value of 255) and those below as white (GL
value of 0). Next, two morphological operations are performed on
the binary image. First, opening (an erosion operation followed by
a dilation operation, iterations=1, count=1), which removes
isolated black pixels. Second, closing (a dilation operation
followed by an erosion operation, iterations=1, count=1), which
fills in small holes. Lastly, use the fill holes operation to fill
in any remaining voids within the pattern elements.
Select the analyze particles function. Set for the analysis to
exclude the edge elements, so that only whole elements are
measured. Set the software to calculate to two decimal places (the
nearest 0.01 mm) the following pattern element parameters: Area,
Perimeter, Feret (length of the element), Feret Angle (angle of
element length) and Minimum Feret (width of the element
perpendicular to the element length). Display and save all of these
measurements for each of the individual elements. In addition to
these measurements, an Aspect Ratio for each element can be
calculated by dividing the element length by its width, as well as,
a Perimeter to Area ratio. Again select the analyze particles
function, but his time set the analysis to include the edge holes
and record the total count of elements identified in the image.
Repeat this procedure for all replicate images.
[0245] c. Inter-Element Distance Measurements
[0246] The average, standard deviation and median distance between
the pattern elements can be measured by further analyzing the
binary image that was analyzed for the pattern element
measurements. First, obtain a duplicate copy of the binary image,
and perform a Voronoi operation. This generates an image of cells
bounded by lines of points having equal distance to the borders of
the two nearest pattern elements, where the pixel values are
outputs from a Euclidian distance map (EDM) of the binary image. An
EDM is generated when each inter-element pixel in the binary image
is replaced with a value equal to that pixel's distance from the
nearest pattern element. Next, remove the background zeros to
enable statistical analysis of the distance values. This is
accomplished by using the image calculator to divide the Voronoi
cell image by itself to generate a 32-bit floating point image
where all of the cell lines have a value of one, and the remaining
parts of the image are identified as Not a Number (NaN). Lastly,
using the image calculator, multiply this image by the original
Voronoi cell image to generate a 32-bit floating point image where
the distance values along the cell lines remain, and all of the
zero values have been replaced with NaN. Next, convert the pixel
distance values into actual inter-element distances by multiplying
the values in the image by the pixel resolution of the image
(0.0606 mm per pixel), and then multiply the image again by 2 since
the values represent the midpoint distance between elements.
Measure and record the mean, standard deviation and median
inter-element distance for the image to the nearest 0.01 mm. Repeat
this procedure for all replicate images.
Pressure Mapping Test Method
[0247] This method is suitable to determine the variation in
pressure that is obtained by pressing a texture, such as described
in FIGS. 16 (Huggies.RTM. NC) and 17 (Pampers.RTM. Sensitive) (both
commercially available non-textured fibrous structures) and FIG. 18
(a textured fibrous structure according to the present invention)
into another surface. A pressure mapping device from Tekscan is
used (Tekscan Pressure Mapping System) together with the I-Scan
software and a pressure sensor 5027 is used. The instrument is
calibrated by placing the pressure senor between two hard and
essentially non-deflecting plates, with the upper plate size
exactly matching the size of the effective area of the sensor, with
the lower plate exceeding the size of the effective of the sensor.
The assembly, consisting of the 2 plates with the sensor between
the 2 plates, is then placed on a flat surface. Additional weights
are then placed on the upper plate to obtain a desired range of
known pressures. The calibration routine available in the I-scan
software is then used to calibrate the instrument. As an example,
calibration weights of 0.1, 0.5, and 1 pound, including the weight
of the upper plate, may be used to create a suitable range of
pressures. The exact range of pressures used for the calibration
and subsequent texture characterization, should however be chosen
based on the relevant pressure range for the intended application
or prediction.
[0248] To measure the pressure distribution generated from a
particular textured sample, a piece of the sample is first cut,
using a pair of scissors, to slightly exceed the size of the
effective area of the sensor. The sensor is then placed on top of a
non-deflecting hard surface, preferably the same plate as used for
the calibration described above. The sample is then placed on top
of the sensor. The smaller plate is them placed on top of the
sample, and carefully positioned to be aligned with the effective
area of the sensor. Additional weights, within the range used for
calibration described above, can then be added on top of the upper
plate to generate the desired total pressure. Positioning of
additional weights needs to be done in such a way as not to create
an uneven pressure distribution on the sample, and need to be
carefully centered on top of the upper plate. The I-scan software
is then used to create a visualization of the pressure
distribution, as shown in FIGS. 16-18.
Liquid Absorptive Capacity Test Method
[0249] The following method, which is modeled after EDANA 10.4-02,
is suitable to measure the Liquid Absorptive Capacity of any
fibrous structure or wipe.
[0250] Prepare 5 samples of a pre-conditioned/conditioned fibrous
structure or wipe for testing so that an average Liquid Absorptive
Capacity of the 5 samples can be obtained.
[0251] Materials/Equipment [0252] 1. Flat stainless steel wire
gauze sample holder with handle (commercially available from
Humboldt Manufacturing Company) and flat stainless steel wire gauze
(commercially available from McMaster-Carr) having a mesh size of
20 and having an overall size of at least 120 mm.times.120 mm
[0253] 2. Dish of size suitable for submerging the sample holder,
with sample attached, in a test liquid, described below, to a depth
of approximately 20 mm [0254] 3. Binder Clips (commercially
available from Staples) to hold the sample in place on the sample
holder [0255] 4. Ring stand [0256] 5. Balance, which reads to four
decimal places [0257] 6. Stopwatch [0258] 7. Test liquid: deionized
water (resistivity >18 megaohmscm)
[0259] Procedure
[0260] Prepare 5 samples of a fibrous structure or wipe for 5
separate Liquid Absorptive Capacity measurements. Individual test
pieces are cut from the 5 samples to a size of approximately 100
mm.times.100 mm, and if an individual test piece weighs less than 1
gram, stack test pieces together to make sets that weigh at least 1
gram total. Fill the dish with a sufficient quantity of the test
liquid described above, and allow it to equilibrate with room test
conditions. Record the mass of the test piece(s) for the first
measurement before fastening the test piece(s) to the wire gauze
sample holder described above with the clips. While trying to avoid
the creation of air bubbles, submerge the sample holder in the test
liquid to a depth of approximately 20 mm and allow it to sit
undisturbed for 60 seconds. After 60 seconds, remove the sample and
sample holder from the test liquid. Remove all the binder clips but
one, and attach the sample holder to the ring stand with the binder
clip so that the sample may vertically hang freely and drain for a
total of 120 seconds. After the conclusion of the draining period,
gently remove the sample from the sample holder and record the
sample's mass. Repeat for the remaining four test pieces or test
piece sets.
[0261] Calculation of Liquid Absorptive Capacity
[0262] Liquid Absorptive Capacity is reported in units of grams of
liquid composition per gram of the fibrous structure or wipe being
tested. Liquid Absorptive Capacity is calculated as follows for
each test that is conducted:
LiquidAbsorptive Capacity = M X - M i M i ##EQU00003##
In this equation, M.sub.i is the mass in grams of the test piece(s)
prior to starting the test, and M.sub.X is the mass in grams of the
same after conclusion of the test procedure. Liquid Absorptive
Capacity is typically reported as the numerical average of at least
five tests per sample.
Pore Volume Distribution Test Method
[0263] Pore Volume Distribution measurements are made on a
TRI/Autoporosimeter (TRI/Princeton Inc. of Princeton, N.J.). The
TRI/Autoporosimeter is an automated computer-controlled instrument
for measuring pore volume distributions in porous materials (e.g.,
the volumes of different size pores within the range from 2.5 to
1000 .mu.m effective pore radii). Complimentary Automated
Instrument Software, Release 2000.1, and Data Treatment Software,
Release 2000.1 is used to capture, analyze and output the data.
More information on the TRI/Autoporosimeter, its operation and data
treatments can be found in The Journal of Colloid and Interface
Science 162 (1994), pgs 163-170, incorporated here by
reference.
[0264] As used in this application, determining Pore Volume
Distribution involves recording the increment of liquid that enters
a porous material as the surrounding air pressure changes. A sample
in the test chamber is exposed to precisely controlled changes in
air pressure. The size (radius) of the largest pore able to hold
liquid is a function of the air pressure. As the air pressure
increases (decreases), different size pore groups drain (absorb)
liquid. The pore volume of each group is equal to this amount of
liquid, as measured by the instrument at the corresponding
pressure. The effective radius of a pore is related to the pressure
differential by the following relationship.
Pressure differential=[(2).gamma. cos .THETA.]/effective radius
where .gamma.=liquid surface tension, and .THETA.=contact
angle.
[0265] Typically pores are thought of in terms such as voids, holes
or conduits in a porous material. It is important to note that this
method uses the above equation to calculate effective pore radii
based on the constants and equipment controlled pressures. The
above equation assumes uniform cylindrical pores. Usually, the
pores in natural and manufactured porous materials are not
perfectly cylindrical, nor all uniform. Therefore, the effective
radii reported here may not equate exactly to measurements of void
dimensions obtained by other methods such as microscopy. However,
these measurements do provide an accepted means to characterize
relative differences in void structure between materials.
[0266] The equipment operates by changing the test chamber air
pressure in user-specified increments, either by decreasing
pressure (increasing pore size) to absorb liquid, or increasing
pressure (decreasing pore size) to drain liquid. The liquid volume
absorbed at each pressure increment is the cumulative volume for
the group of all pores between the preceding pressure setting and
the current setting.
[0267] In this application of the TRI/Autoporosimeter, the liquid
is a 0.2 weight % solution of octylphenoxy polyethoxy ethanol
(Triton X-100 from Union Carbide Chemical and Plastics Co. of
Danbury, Conn.) in 99.8 weight % distilled water (specific gravity
of solution is about 1.0). The instrument calculation constants are
as follows: .rho. (density)=1 g/cm.sup.3; .gamma. (surface
tension)=31 dynes/cm; cos .THETA.=1. A 0.22 .mu.m Millipore Glass
Filter (Millipore Corporation of Bedford, Mass.; Catalog #
GSWP09025) is employed on the test chamber's porous plate. A
plexiglass plate weighing about 24 g (supplied with the instrument)
is placed on the sample to ensure the sample rests flat on the
Millipore Filter. No additional weight is placed on the sample.
[0268] The remaining user specified inputs are described below. The
sequence of pore sizes (pressures) for this application is as
follows (effective pore radius in .mu.m): 2.5, 5, 10, 15, 20, 30,
40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 225, 250,
275, 300, 350, 400, 500, 600, 800, 1000. This sequence starts with
the fibrous structure or wipe sample dry and saturates it as the
pore settings increase (typically referred to with respect to the
procedure and instrument as the 1.sup.st absorption).
[0269] In addition to the fibrous structure or wipe sample being
tested, a blank condition (no sample between a plexiglass plate and
Millipore Filter) is run to account for any surface and/or edge
effects within the test chamber. Any pore volume measured for this
blank condition is subtracted from the applicable pore grouping of
the fibrous structure or wipe sample being tested. If upon
subtracting the blank condition the result is 0 or negative then
report a 0 for that pore range. This data treatment can be
accomplished manually or with the available TRI/Autoporosimeter
Data Treatment Software, Release 2000.1.
[0270] Percent (%) Total Pore Volume is a percentage calculated by
taking the volume of fluid in the specific pore radii range divided
by the Total Pore Volume. The TRI/Autoporosimeter outputs the
volume of fluid within a range of pore radii. The first data
obtained is for the "5.0 micron" pore radii which includes fluid
absorbed between the pore sizes of 2.5 to 5.0 micron radius. The
next data obtained is for "10 micron" pore radii, which includes
fluid absorbed between the 5.0 to 10 micron radii, and so on.
Following this logic, to obtain the volume held within the range of
91-140 micron radii, one would sum the volumes obtained in the
range titled "100 micron", "110 micron", "120 micron", "130
micron", and finally the "140 micron" pore radii ranges. For
example, % Total Pore Volume 91-140 micron pore radii=(volume of
fluid between 91-140 micron pore radii)/Total Pore Volume. Total
Pore Volume is the sum of all volumes of fluid between 2.5 micron
and 1000 micron pore radii.
Basis Weight Test Method
[0271] Basis weight is measured prior to the application of any
end-use lotion, cleaning solution, or other liquid composition,
etc. to the fibrous structure or wipe, and follows a modified EDANA
40.3-90 (February 1996) method as described herein below. [0272] 1.
Cut at least three test pieces of the fibrous structure or wipe to
specific known dimensions, preferably using a pre-cut metal die and
die press. Each test piece typically has an area of at least 0.01
m.sup.2. [0273] 2. Use a balance to determine the mass of each test
piece in grams; calculate basis weight (mass per unit area), in
grams per square meter (gsm), using equation (1).
[0273] Basis Weight = Mass of Test Piece ( g ) Area of Test Piece (
m 2 ) ( 1 ) ##EQU00004## [0274] 3. For a fibrous structure or wipe
sample, report the numerical average basis weight for all test
pieces. [0275] 4. If only a limited amount of the fibrous structure
or wipe is available, basis weight may be measured and reported as
the basis weight of one test piece, the largest rectangle possible.
[0276] 5.
Dynamic Absorption Time (DAT) Test Method
[0277] DAT provides a measure of the ability of the fibrous
structure or wipe to absorb a test liquid and the time it takes for
the test liquid to be absorbed by the fibrous structure or wipe,
which is in turn used as a measure of how well a fibrous structure
or wipe will absorb liquid into the fibrous structure or wipe.
[0278] The DAT test method measures the dimensions of a drop of a
liquid composition, in this case a drop of a lotion, from the
moment it is in contact with a fibrous structure or wipe to when
the drop is absorbed by the fibrous structure or wipe. The method
also measures the rate of change of the dimensions of the drop with
respect to time. Fibrous structures or wipes characterized by low
DAT and low initial contact angle values may be more absorbent than
those characterized by higher DAT and/or higher initial contact
angle values.
[0279] Dynamic Absorbency Test (DAT) measurements of a fibrous
structure or wipe are made utilizing a Thwing Albert DAT Fibro 1100
(Thwing Albert, Pa.). The DAT Fibro 1100 is an automated
computer-controlled instrument for measuring contact angle of a
drop of a liquid composition on porous materials and the time it
takes for the drop of a liquid composition to absorb into the
fibrous structure or wipe. Contact angle refers to the angle formed
by the fibrous structure or wipe and the tangent to the surface of
the liquid composition drop in contact with the fibrous structure
or wipe. More information on absorbency of sheet materials using an
automated contact angle tester can be found in ASTM D 5725-95.
[0280] The DAT contact angle measurements provide a means that is
used in the art to characterize relative differences in absorbent
properties of materials.
[0281] The equipment operates by controlling the volume and the
ejection pulse of a small drop of a liquid composition discharged
directly onto the surface of a fibrous structure or wipe. The
height, base and angle produced as the liquid composition drop
settles and becomes absorbed into the fibrous structure or wipe are
determined based on an internal calibrated gray scale. In this
application, a DAT Fibro 1100 series model (high speed camera
resolution for porous absorbent paper substrates) is calibrated
according to the manufacturer's instructions and using a 0.292
calibration sled. The instrument is set to discharge a 4 microliter
(.mu.L) drop of a liquid composition, a stroke pulse of 8, canula
tip of 340, drop bottom of 208, and paper position of 134.
[0282] The fibrous structure or wipe samples to be tested are cut
to approximately 0.5 inches in length and not exceeding the width
of the sample sled associated with the testing equipment. The
fibrous structure or wipe samples are cut along the MD direction of
the fibrous structure or wipe to minimize neckdown and structural
changes during handling. The fibrous structure or wipe samples as
well as the liquid composition(s) to be dropped onto the fibrous
structures or wipes are allowed to equilibrate to
23.degree..+-.2.2.degree. C. and 50% relative humidity for at least
4 hours. The liquid composition(s) are prepared by filling a clean
dry syringe (0.9 mm diameter, part #1100406, Thwing Albert) at
least half way. The syringe should be rinsed with the liquid
composition of interest prior to the test and this can be achieved
by filling/emptying the syringe 3 consecutive times with the liquid
composition. In the present measurements, the liquid composition
used is an aqueous composition that contains distilled water and a
nonionic surfactant; namely, Triton.RTM. X 100, which is
commercially available from Dow Chemical Company, at levels to
result in the aqueous composition exhibiting a surface tension of
30 dynes/cm. The fibrous structure or wipe and the liquid
composition are loaded into the instrument according to the
manufacturer's instructions. The controlling software is designed
to eject the liquid composition onto the fibrous structure or wipe
and measure the following parameters: time for the liquid
composition to absorb into fibrous structure or wipe, contact
angle, base, height, and volume.
[0283] A total of 10 measurements of the time the liquid
composition drop takes to be absorbed by the fibrous structure or
wipe for each side of the fibrous structure or wipe are made. The
reported DAT value (in seconds) is the average of the 20
measurements (10 from each side) of a fibrous structure or
wipe.
Soil Leak Through Test Method
[0284] The following method is used to measure the soil leak
through value for a fibrous structure or wipe.
[0285] First, prepare a test composition to be used in the soil
leak through test. The test composition is prepared by weighing out
8.6 g of Great Value Instant chocolate pudding mix (available from
WalMart--do not use LowCal or Sugar Free pudding mix). Add 10 mL of
distilled water to the 8.6 g of mix. Stir the mix until smooth to
form the pudding. Cover the pudding and let stand at 23.degree.
C..+-.2.2.degree. C. for 2 hours before use to allow thorough
hydration of the pudding mix.
[0286] The Great Value Instant chocolate pudding mix can be
purchased at
http://www.walmart.com/ip/Great-Value-Chocolate-Instant-Pudding-3.9-oz/10-
534173. The ingredients listed on the Great Value Instant chocolate
pudding mix are the following: Sugar, Modified Food Starch,
Dextrose, Cocoa Powder Processed With Alkali, Disodium Phosphate,
Contains 2% Or Less Of Nonfat Dry Milk, Tetrasodium Pyrophosphate,
Salt, Natural And Artificial Flavoring, Mono- And Diglycerides
(Prevent Foaming), Palm Oil, Red 40, Yellow 5, Blue 1. Titanium
Dioxide (For Color). Allergy Warning: Contains Milk. May Contain
Traces Of Eggs, Almonds, Coconut, Pecans, Pistachios, Peanuts,
Wheat And Soy.
[0287] Transfer the test composition to a syringe using a sterile
tongue depressor for ease of handling.
[0288] Tare weight of a piece of wax paper. The basis weight of the
wax paper is about 35 gsm to about 40 gsm. Wax paper is supplied
from the Reynolds Company under the Cut-Rite brand name. Weigh out
0.6.+-.0.05 g of the test composition on the wax paper. Prepare 5
samples of a fibrous structure or wipe to be tested. The 5 samples
of fibrous structure or wipe are cut, if necessary to dimensions of
150 mm.times.150 mm. One of the 5 samples will be the control
sample (no test composition will be applied to it). On a flat
surface, place the wax paper with the test composition onto one of
the remaining 4 test samples of fibrous structure or wipe that has
been folded in half to create a two-ply structure such that the
test composition is positioned between an exterior surface of the
fibrous structure or wipe and the wax paper. Gently place a 500 g
balance weight with a 15/8 inch diameter (yielding about 0.5 psi)
on the wax paper, e.g.,) for 10 seconds making sure not to press on
the weight when placing the weight on the wax paper. 500 gram
balance weights are available from the McMaster-Carr Company. After
the 10 seconds, remove the weight and gently unfold the fibrous
structure or wipe. Examine the soil color visible from the interior
surface of the de facto "second ply" (the surface of the portion of
the fibrous structure or wipe that is facing inward and is not the
backside of the portion of the fibrous structure or wipe to which
the test composition was applied). A Hunter Color Lab Scan is used
to examine this interior surface. The color may diffuse over time;
so examine the wipes at a consistent time interval (within 10
minutes after placing the weight on the wax paper) for better
sample to sample comparison. Repeat the test composition
application procedure for the remaining test samples of fibrous
structure or wipe.
[0289] The color present on the interior surface of each test
sample of fibrous structure or wipe to be analyzed is then analyzed
using a Hunter Color Lab instrument.
[0290] Hunter Color Lab Scan Procedure
[0291] (Calibration)
[0292] 1. Set scale to XYZ.
[0293] 2. Set observer to 10.
[0294] 3. Set both illuminations to D65.
[0295] 4. Set procedure to none and click ok.
[0296] 5. Check to see if read procedures is set to none.
[0297] 6. Place green plate on port and click read sample. Enter
sample ID green.
[0298] 7. Place white plate on port and click read sample. Enter
sample ID white.
[0299] 8. Open calibration excel file, click on file save as and
enter today's date.
[0300] 9. Go back to test page of hunter color and highlight
XY&Z numbers, click on edit, copy.
[0301] 10. Open up today's calibration sheet and paste numbers in
the value read cell. Check value read to actual value. Values must
be within specs to pass.
[0302] 11. Printout calibration report.
[0303] (Test)
[0304] 1. Click on active view.
[0305] 2. Set Scale to Cielab.
[0306] 3. Set both illuminate to C.
[0307] 4. Set observer to 2.
[0308] 5. Set procedure to none.
[0309] 6. Click ok.
[0310] 7. Click clear all.
[0311] 8. Scan the control sample to measure and record the L value
of the control sample.
[0312] 9. After removing the weight from a test sample of fibrous
structure or wipe as described above, unfold the test sample and
place the test sample of fibrous structure or wipe on instrument
port such that the color of the interior surface of the de facto
"second ply" as described above can be analyzed. Place a fresh
piece of wax paper on top of the test sample to avoid contaminating
the instrument.
[0313] 10. Click read sample to measure and record the L value of
the test sample. Enter name of sample. Click ok. Repeat for the
remaining test samples.
[0314] 11. After the L values of the 4 test samples have been
measured and recorded, average the L values for the 4 test
samples.
[0315] 12. Calculate the Soil Leak Through Lr Value for the fibrous
structure or wipe tested by determining the difference between the
L value of the control sample and the average L value of the 4 test
samples.
[0316] The reported Soil Leak Through Lr Value is the difference in
the L color value from the Hunter Color Lab between the control
sample and the test sample of the fibrous structure or wipe. A Soil
Leak Through Lr Value of less than 20 and/or less than 15 and/or
less than 10 and/or less than 5 and/or less than 2 is desirable.
The lower the value, the more the fibrous structure or wipe
prevents soil leak through.
[0317] A suitable equivalent to the Great Value Instant chocolate
pudding mix test composition can be made by the following procedure
for use in the test method described above.
[0318] First, a test composition for testing purposes is prepared.
In order to make the test composition, a dry powder mix is first
made. The dry powder mix comprises dehydrated tomato dices (Harmony
House or NorthBay); dehydrated spinach flakes (Harmony House or
NorthBay); dehydrated cabbage (Harmony House or NorthBay); whole
psyllium husk (available from Now Healthy Foods that has to be
sieved with 600 .mu.m cutoff to collect greater than 600 .mu.m
particles and then ground to collect 250-300 .mu.m particles)
(alternatively available from Barry Farm as a powder that has to be
sieved to collect 250-300 .mu.m particles); palmitic acid (95% Alfa
Aeser B20322); and calcium stearate (Alfa Aeser 39423). Next add
food grade yeast powders commercially available as Provesta.RTM.
000 and Ohly.RTM. HTC (both commercially available from Ohly
Americas, Hutchinson, Minn.).
[0319] If grinding of the vegetables needs to be performed, an IKA
All basic grinder (commercially available from VWR or Rose
Scientific LTD) is used. To grind the vegetables, add the vegetable
flakes to the grinding bowl. Fill to the mark (within the metal
cup, do not over fill). Power on for 5 seconds. Stop. Tap powder 5
times. Repeat power on (for 5 seconds), stop and tap powder (5
times) procedure 4 more times. Sieve the ground powder by stacking
a 600 .mu.m opening sieve on top of a 300 .mu.m opening sieve such
that powders of 300 .mu.m or less are collected. Regrind any
remaining powders that are larger than 300 .mu.m one time. Collect
powders of 300 .mu.m or less.
[0320] The test composition is prepared by mixing the above
identified ingredients in the following levels in Table 3
below.
TABLE-US-00002 TABLE 3 Soil Powder Premix Grams % Tomato Powder
20.059 18.353 Psyllium Husk 0.599 0.548 Cabbage 2.145 1.963 Spinach
Powder 8.129 7.438 Provesta 000 40.906 37.428 Ohly HCT 16.628
15.214 Palmitic acid/Calcium Stearate (2:1) 20.827 19.056
[0321] The palmitic acid/calcium stearate blend is prepared by
grinding together and collecting powders of 300 .mu.m or less from
a blend of 20.0005 g palmitic acid and 10.006 g calcium
stearate.
[0322] To make up the test composition, 21 g of distilled water at
23.degree. C..+-.2.2.degree. C. is added to every 9 g of the soil
powder premix described above in Table 3 used in a suitable
container. A tongue depressor is used to stir the composition until
the composition, which may be a paste, is homogeneous, about 2
minutes of stirring. Cover the container loosely with a piece of
aluminum foil and let stand for 2 hours at
23.degree..+-.2.2.degree. C. Next add 4 drops of FD&C Red Dye
#40 and stir until completely mixed, about 2 minutes of stirring.
The test composition is ready for use in the soil leak through
test.
CD Wet Initial Tensile Strength Test Method
[0323] The CD Wet Initial Tensile Strength of a fibrous structure
or wipe is determined using a modified EDANA 20.2.89 method, which
generally sets forth the following test method.
[0324] Cut 5--50.+-.0.5 mm wide (MD) and more than 150 mm long (CD)
test strips (so that a distance of 100 mm can be obtained between
the jaws of the dynamometer) of the fibrous structure or wipe to be
tested with a laboratory paper cutter or a template and scalpel
(not scissors, as the test pieces must be cut out cleanly according
to ERT 130).
[0325] Using a tensile testing machine (dynamometer) with a
constant rate of extension (100 mm/min) and jaws 50 mm wide
(capable of holding the cut sample securely across their full
widths without damage) and fitted with a system for recording
force--elongation curves.
[0326] Place a strip to be tested in the jaws of the tensile
testing machine, the jaws being 100 mm.+-.1 mm apart.
[0327] Apply a constant rate of extension (100 mm/min) and record
the force-elongation curve.
[0328] Discard the results from any test strip where the break
occurs in the clamp or where any break reaches the jaws.
[0329] Establish the scale of force-elongation curve. Use the
force-elongation curve to determine the CD Wet Initial Tensile
Strength in newtons (N). If several peak values for the applied
force occur during the test, take the highest value as the CD Wet
Initial Tensile Strength of the strip and note this in the test
report. Repeat the procedure on additional strips from the fibrous
structure wipe to get an average CD Wet Initial Tensile Strength
from 5 samples, which is the reported CD Wet Initial Tensile
Strength in N to the nearest 0.1 N.
Lotion Release Test Method
[0330] The lotion release of a fibrous structure or wipe is
determined by wiping the fibrous structure or wipe over a defined
area, using a defined pressure and default speed of the
instrument.
[0331] A wiping apparatus capable of simulating a wiping process is
used. A suitable wiping apparatus is available from Manfred Fuhrer
GmbH, D-60489 Frankfurt, GERMANY. The wiping apparatus has a
surface on which a skin analogue (a self-adhesive DC fix foil 40
cm.times.40 cm available from Konrad Hornschuch AG, 74679
Weissbach, GERMANY,) is placed. The wiping apparatus further has a
mechanical arm with a wiping hand (180 mm.times.78 mm) attached
that applies a wiping pressure of 8.5 g/cm.sup.2 to the skin
analog.
[0332] To run the test, place the skin analogue on the surface of
the wiping apparatus. With nitrile/powder free gloves on, weigh a
fibrous structure or wipe to be tested to get its initial mass.
Unfold the fibrous structure or wipe, if folded, and place it onto
the already stuck skin analogue. Gently place the wiping hand on
the top of the fibrous structure or wipe. Tightly attach the
fibrous structure or wipe to the wiping hand such that only a 180
mm.times.78 mm portion of the fibrous structure or wipe will come
into contact with the skin analogue when the wiping movements of
the wiping hand are performed. Ensure that the wiping apparatus is
on and perform 3 wiping movements. The first wiping movement is a
90.degree. stroke of the wiping arm including the wiping hand and
fibrous structure or wipe attached thereto. The second wiping
movement is a 90.degree. return stroke over the same portion of the
skin analogue that the first wiping movement traveled. The third
wiping movement is another 90.degree. stroke of the wiping arm
including the wiping hand and fibrous structure or wipe attached
thereto, like the first wiping movement, and it travels over the
same portion of the skin analogue as the first and second wiping
movements. Carefully remove the fibrous structure or wipe from the
wiping hand being careful not to wipe the fibrous structure or wipe
on the skin analogue while removing it from the wiping hand. Weigh
the fibrous structure or wipe again to obtain the final mass. The
lotion release for the fibrous structure or wipe is the difference
between the initial mass of the fibrous structure or wipe and the
final mass of the fibrous structure or wipe. Clean the skin
analogue with a dry tissue. Repeat the procedure again starting
with weighing the next fibrous structure or wipe to get its initial
mass. The reported lotion release value is the average lotion
release value of 10 tested fibrous structures or wipes
[0333] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0334] All documents cited in the Detailed Description of the
Invention are, in relevant part, incorporated herein by reference;
the citation of any document is not to be construed as an admission
that it is prior art with respect to the present invention. To the
extent that any meaning or definition of a term in this document
conflicts with any meaning or definition of the same term in a
document incorporated by reference, the meaning or definition
assigned to that term in this document shall govern.
[0335] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *
References